haulmaax rear suspension - hendrickson...introduction 2 17730-244 haulmaax® rear suspension section...

HAULMAAX® Rear SuspensionSUBJECT: Service InstructionsLIT NO: 17730-244DATE: October 2019 REVISION: I

TABLE OF CONTENTS

Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . .2

Section 2 Product Description . . . . . . . . . . . . . . . .2

Section 3 Important Safety Notice . . . . . . . . . . . . .5

Section 4 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . .8

Section 5 Special Tools . . . . . . . . . . . . . . . . . . . . .14

Section 6 Preventive MaintenanceProgressive Load Spring Pre-Delivery

Inspection . . . . . . . . . . . . . . . . . . . . . .16

Hendrickson Recommended Inspection Intervals . . . . . . . . . . . . . . .16

Component Inspection . . . . . . . . . . . . . . .17

Longitudinal and Transverse Torque Rods .17

Bolster Springs . . . . . . . . . . . . . . . . . . . . .18

Load Springs – Progressive or Auxiliary . . .19

Wear Plates . . . . . . . . . . . . . . . . . . . . . . . .20

Rebound Straps . . . . . . . . . . . . . . . . . . . .20

Equalizing Beam End Connection . . . . . . .20

Axle Bracket . . . . . . . . . . . . . . . . . . . . . . .22

Bar Pin End Bushings . . . . . . . . . . . . . . . .23

Bar Pin Shims . . . . . . . . . . . . . . . . . . . . . .23

Shock Absorbers (if equipped) . . . . . . . . .24

Section 7 Alignment & AdjustmentsDrive Axle Alignment . . . . . . . . . . . . . . . . .26

Lateral Alignment . . . . . . . . . . . . . . . . . . .27

Bar Pin with Shims Alignment . . . . . . . . . .28

Load Spring Shim Evaluation . . . . . . . . . . .30

Load Spring Shim Adjustment . . . . . . . . . .31

Section 8 Component ReplacementFasteners . . . . . . . . . . . . . . . . . . . . . . . . .32

Outboard Frame Bracket . . . . . . . . . . . . . .32

Inboard Frame Bracket . . . . . . . . . . . . . . .33

Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Load Springs – Progressive or Auxiliary . . .37

Standard Rebound Straps . . . . . . . . . . . . .38

Production Dual Rebound Straps – Outrigger Applications . . . . . . . . . . . . .39

Bolster Springs . . . . . . . . . . . . . . . . . . . . .40

Shock Absorbers (if equipped) . . . . . . . . .43

Equalizing Beam . . . . . . . . . . . . . . . . . . . .43

Bar Pin End Bushings . . . . . . . . . . . . . . . .49

Longitudinal Torque Rods . . . . . . . . . . . . . .51

Transverse Torque Rods . . . . . . . . . . . . . . .52

Torque Rod Bushings . . . . . . . . . . . . . . . . .53

Aftermarket Shock Absorber Kits . . . . . . . .56

Aftermarket Dual Rebound Strap Kit for Outrigger Applications . . . . . . . .58

Section 9 Torque Specifications . . . . . . . . . . . . . .62

Section 10 Troubleshooting Guide . . . . . . . . . . . . .66

Introduction 2 17730-244

HAULMAAX® Rear Suspension

SECTION 1

IntroductionThis publication is intended to acquaint and assist maintenance personnel in the preventive maintenance, service, repair and rebuild of the HAULMAAX® rear suspension system .

NOTE Use only Genuine Hendrickson parts for servicing this suspension system .

It is important to read and understand the entire Technical Procedure publication prior to perform-ing any maintenance, service, repair, or rebuild of this product . The information in this publication contains parts lists, safety information, product specifications, features, proper maintenance, service, repair and rebuild instructions for the HAULMAAX Suspension .

Hendrickson reserves the right to make changes and improvements to its products and publications at any time . Contact Hendrickson Tech Services for information on the latest version of this manual at 1-866-755-5968 (toll-free U .S . and Canada), 1-630-910-2800 (outside U .S . and Canada) or e-mail: techservices@hendrickson-intl .com .

The latest revision of this publication is also available online at www.hendrickson‑intl.com .

SECTION 2

Product DescriptionAdvanced engineering design methods and experience gathered from millions of Hendrickson suspensions created HAULMAAX, a rugged, yet lightweight rubber vocational rear suspension that saves weight over competitive suspensions for greater payloads and route consolidation .

Suspension weight is reduced for greater payloads and improved durability through innovative design, higher strength materials and advanced manufacturing methods . Proven with extensive vehicle durability and laboratory testing, HAULMAAX delivers the reliability and quality you’ve come to expect from Hendrickson, the leader in suspension technology .

The HAULMAAX spring system easily adjusts to the load for an enhanced combination of empty-ride quality and loaded stability . Most importantly, this innovative suspension significantly reduces wheel hop by eliminating the fixed pivot point found in the center bushings of other walking-beam suspensions .

Extra wide bolster spring centers and a unique progressive load spring provide exceptional stabil-ity for demanding applications such as refuse, concrete mixers and dump .

■ Equalizing beam — Formed and robotically-welded equalizing beam provides a narrow profile for weight savings, distributes load equally between both axles for improved traction, lowers the center of gravity to increase stability, and establishes a solid axle connection for improved handling . The center bushing is also eliminated for reduced maintenance .

■ Bar pin end connection — Rugged axle connection extends bushing life, and allows easy axle alignment and serviceability .

■ Saddle and frame brackets — Lightweight, modular design simplifies installation .

17730-244 3 Product Description


■ Hendrickson torque rods — Improve cornering by controlling lateral forces . Transverse torque rods ensure maximum lateral axle control and straight line suspension stability . Longitudinal torque rods engineered to optimize resistance to wind up during acceleration and braking .

■ Progressive load springs — Newly designed to always engage for smoother ride and addi-tional stability, and eliminate shim adjustments for lower maintenance (for most applications) .

■ Premium rubber bolster springs — The unique design works with the progressive load springs to deliver enhanced empty ride quality and loaded stability .

■ Optional shock absorbers — Provide additional driver comfort . Shock absorbers are required for tractor and logging applications . Available as production or aftermarket options .

■ Tie‑bar design — Achieves greater column stiffness, improves suspension performance even when axles are misaligned, remains consistent with the ride quality and stability of the origi-nal design . The tie-bar design is equipped on the 46K capacity and an aftermarket option for 40K capacity .

FIGURE 2‑1

Product Description 4 17730-244


HAULMAAX SPECIFICATIONS 40K 46K

Installed Weight1 (54" axle spacing) 855 lbs . 861 lbs .

Suspension Rating 40,000 lbs . 46,000 lbs .

Gross Vehicle Weight (GVW) Approval2 73,000 lbs . 80,000 lbs .

Gross Combination Weight (GCW) Approval 160,000 lbs . 190,000 lbs .

Site Travel Rating3 55,000 lbs . 60,000 lbs .

Diagonal Articulation4 17 inches

Lift Axles Approved

Ride Heights (loaded)5 9 .5", 10 .5", 11 .5", 13 .25", 15 .5"

Axle Spacing6 52", 54", 60", 72 .5"

Shock Absorber Applications7 Tractors, Logging

Hendrickson approves the use of HAULMAAX in the following vocational truck applications: dump, concrete mixer, refuse, logging, crane / boom, platform and fire / rescue .

1 . Installed weight includes complete suspension, torque rods, axle brackets and frame brackets; add 31 pounds for shock absorbers .

2 . Contact Hendrickson for applications that may exceed GVW approval ratings .

3 . Job site travel rating – operators using vehicles equipped with liftable pusher or tag axles must not exceed published ratings . Job-site ratings are limited to no more than five percent of vehicle operation at speed not to exceed five mph . Liftable pusher or tag axles should only be raised (or unloaded) to improve vehicle maneuverability in job site applications or when vehicle is empty . Job site travel ratings are consistent with published axle manufacturer’s limitations . Axle and suspension job site travel specifications must not be exceeded .

4 . Suspension articulation may exceed vehicle’s capability and may be limited by vehicle manufacturer; vehicle manufacturer installed axle stops may restrict suspension’s articulation .

5 . HAULMAAX ride height measurements are taken from the centerline of the axle to the bottom of the truck frame .

6 . Contact Hendrickson for availability of beam lengths .

7 . Shock absorbers are required in tractor and logging applications . Ride and traction may be improved in other applications with shock absorbers . Ride performance can be subjective and may be dependent on many factors beyond the suspension design such as cab suspension, road conditions, body / auxiliary equipment, frame specifications, etc . Contact Hendrickson or your truck manufacturer / dealer for further information .

17730-244 5 Important Safety Notice


SECTION 3

Important Safety NoticeProper maintenance, service and repair are important to the reliable operation of the suspension . The procedures recommended by Hendrickson and described in this technical publication are methods of performing such maintenance, service and repair .

This technical publication should be read carefully to help prevent personal injury and to assure that proper methods are used . Improper maintenance, service or repair may damage the vehicle, cause personal injury, render the vehicle unsafe in operation, or void the manufacturer’s warranty .

Failure to follow the safety precautions in this manual can result in personal injury and/or property damage . Carefully read and understand all safety related information within this publication, on all decals and in all such materials provided by the vehicle manufacturer before conducting any maintenance, service or repair .

■ EXPLANATION OF SIGNAL WORDSHazard “Signal Words” (Danger-Warning-Caution) appear in various locations throughout this publication . Information accented by one of these signal words must be observed to help mini-mize the risk of personal injury to service personnel, or possibility of improper service methods which may damage the vehicle or render it unsafe .

This is the safety alert symbol . It is used to alert you to potential personal injury haz-ards . Obey all safety messages that follow this symbol to avoid possible injury or death .

Additional ‘Notes’ or ‘Service Hints’ are utilized to emphasize areas of procedural importance and provide suggestions for ease of repair . The following definitions indicate the use of these signal words as they appear throughout the publication .

INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH .

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, CAN RESULT IN DEATH OR SERIOUS INJURY .

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY .

NOTE An operating procedure, practice condition, etc ., which is essential to emphasize .

SERVICE HINT A helpful suggestion that will make the service being performed a little easier and/or faster .

Also note that particular service operations may require the use of special tools designed for specific purposes . These special tools can be found in the Special Tools Section of this publication .

The torque symbol alerts you to tighten fasteners to a specified torque value . Refer to Torque Specifications Section of this publication .

Important Safety Notice 6 17730-244


■ SAFETY PRECAUTIONS FASTENERS

DISCARD USED FASTENERS . ALWAYS USE NEW FASTENERS TO COMPLETE A REPAIR . FAILURE TO DO SO COULD RESULT IN FAILURE OF THE PART OR MATING PARTS, ADVERSE VEHICLE HANDLING, PERSONAL INJURY, OR PROPERTY DAMAGE .

LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE, ADVERSE VEHICLE HANDLING, PROPERTY DAMAGE, OR SEVERE PERSONAL INJURY . MAINTAIN CORRECT TORQUE VALUES AT ALL TIMES . CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED, USING A TORQUE WRENCH THAT IS REGULARLY CALIBRATED . TORQUE VALUES SPECIFIED IN THIS TECHNICAL PUBLICATION ARE FOR HENDRICKSON SUPPLIED FASTENERS ONLY . IF NON HENDRICKSON FASTENERS ARE USED, FOLLOW TORQUE SPECIFICATION LISTED IN THE VEHICLE MANUFACTURER’S SERVICE MANUAL .

LOAD CAPACITYADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSION . ADD-ON AXLE ATTACHMENTS AND OTHER LOAD TRANSFERRING DEVICES CAN INCREASE THE SUSPENSION LOAD ABOVE ITS RATED AND APPROVED CAPACITIES, WHICH CAN RESULT IN COMPONENT DAMAGE AND ADVERSE VEHICLE HANDLING, POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE .

MODIFYING COMPONENTSDO NOT MODIFY OR REWORK PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON . DO NOT SUBSTITUTE REPLACEMENT COMPONENTS NOT AUTHORIZED BY HENDRICKSON . USE OF MODIFIED, REWORKED, SUBSTITUTE OR REPLACEMENT PARTS NOT AUTHORIZED BY HENDRICKSON MAY NOT MEET HENDRICKSON’S SPECIFICATIONS, AND CAN RESULT IN FAILURE OF THE PART, ADVERSE VEHICLE HANDLING, POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE, AND WILL VOID ANY APPLICABLE WARRANTIES . USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS .

TORCH/WELDINGDO NOT USE A CUTTING TORCH TO REMOVE ANY FASTENERS . THE USE OF HEAT ON SUSPENSION COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF THESE PARTS . A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING MAINTENANCE IN THE AREA OF THE EQUALIZING BEAM . DO NOT CONNECT ARC WELDING GROUND LINE TO THE EQUALIZING BEAM . DO NOT STRIKE AN ARC WITH THE ELECTRODE ON THE EQUALIZING BEAM AND AXLE . DO NOT USE HEAT NEAR THE EQUALIZING BEAM ASSEMBLY . DO NOT NICK OR GOUGE THE EQUALIZING BEAM . SUCH IMPROPER ACTIONS CAN DAMAGE THE EQUALIZING BEAM ASSEMBLY, AND CAN CAUSE ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

TRANSVERSE RODSTHE HAULMAAX SUSPENSION INCORPORATES TRANSVERSE RODS FOR VEHICLE STABILITY . IF THESE COMPONENTS ARE DISCONNECTED OR ARE NON-FUNCTIONAL THE VEHICLE SHOULD NOT BE OPERATED . FAILURE TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE TIRE CONTACT WITH THE FRAME . OPERATING A VEHICLE WITH NON-FUNCTIONAL TRANSVERSE TORQUE RODS CAN RESULT IN ADVERSE VEHICLE HANDLING, SEVERE PERSONAL INJURY, AND PREMATURE COMPONENT DAMAGE .

PERSONAL PROTECTIVE EQUIPMENTALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE MAINTE NANCE, REPAIR OR SERVICE .

17730-244 7 Important Safety Notice


PROCEDURES AND TOOLSA TECHNICIAN USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOM MENDED BY HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE VEHICLE’S SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED . INDIVIDUALS DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED WILL ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED .

SUPPORT THE VEHICLE PRIOR TO SERVICINGPLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO PREVENT THE VEHICLE FROM MOVING OR ROLLING . DO NOT WORK AROUND OR UNDER A RAISED VEHICLE SUPPORTED BY ONLY A FLOOR JACK OR OTHER LIFTING DEVICE . ALWAYS SUPPORT A RAISED VEHICLE WITH RIGID SAFETY STANDS . FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY OR DAMAGE TO EQUIPMENT .

LOAD SPRING SHIMAT LEAST ONE (1) LOAD SPRING SHIM MUST BE EQUIPPED ON EACH SIDE OF THE HAULMAAX SUSPENSION . FAILURE TO DO SO CAN CAUSE PREMATURE COMPONENT WEAR, EQUALIZING BEAM MISALIGNMENT, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

IMPROPER VEHICLE LIFT OR SUPPORT METHODIMPROPER VEHICLE LIFT OR SUPPORT METHOD CAN CAUSE DAMAGE TO HAULMAAX REAR SUSPENSION BOLSTER SPRINGS, AND CAN VOID ANY WARRANTY COVERAGE . DO NOT LIFT OR SUPPORT THE VEHICLE AT ONLY ONE OF THE TWO REAR DRIVE AXLES . WHEN LIFTING OR SUPPORTING THE VEHICLE USING THE DRIVE AXLES, ENSURE BOTH DRIVE AXLES ARE LIFTED AND SUPPORTED TOGETHER . READ, UNDERSTAND AND COMPLY WITH ANY ADDITIONAL VEHICLE LIFT AND SUPPORT INSTRUCTIONS PROVIDED BY THE VEHICLE MANUFACTURER OR LIFT EQUIPMENT MANUFACTURER .

PARTS CLEANINGSOLVENT CLEANERS CAN BE FLAMMABLE, POISONOUS, AND CAUSE BURNS . TO HELP AVOID SERIOUS PERSONAL INJURY, CAREFULLY FOLLOW THE MANUFACTURER’S PRODUCT INSTRUCTIONS AND GUIDELINES AND THE FOLLOWING PROCEDURES:

1 . WEAR PROPER EYE PROTECTION .

2 . WEAR CLOTHING THAT PROTECTS YOUR SKIN .

3 . WORK IN A WELL-VENTILATED AREA .

4 . DO NOT USE GASOLINE OR SOLVENTS THAT CONTAIN GASOLINE . GASOLINE CAN EXPLODE .

5 . ACIDIC SOLUTIONS CANNOT BE USED ON ALUMINUM COMPONENTS .

6 . HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY . FOLLOW THE MANUFACTURER’S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY TO HELP PREVENT PERSONAL ACCIDENT OR INJURY .

DO NOT USE HOT SOLU TION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR POLISHED PARTS . DOING SO WILL CAUSE DAMAGE TO THE PARTS AND VOID WARRANTY .


Parts List 8 17730-244

SECTION 4

Parts List40K•46K Capacity

VEHICLE KEY NO. PART NO. DESCRIPTION QTY.



17730-244 9 For all (*) see Notes on Page 10

1 ****Equalizing Beam Assembly, 40K • 46K 2 64846-003 52", with Shock Bracket 64847-003 52", without Shock Bracket 64846-001 54", with Shock Bracket 64847-001 54", without Shock Bracket 64846-002 60", with Shock Bracket 64847-002 60", without Shock Bracket ****Equalizing Beam Assembly, 40K • 46K,

with dual straps 64846-006 52", with Shock Bracket 64847-006 52", without Shock Bracket 64846-004 54", with Shock Bracket 64847-004 54", without Shock Bracket 64846-005 60", with Shock Bracket 64847-005 60", without Shock Bracket Bar Pin End Bushing Service Kit, One Wheel End,

Includes Key Nos . 2-6a 34013-088L Shim Type 34013-188L Rotating, Shim Type2 *Bar Pin Bushing 4 34013-104 Bar Pin End Bushing Fastener Kit, One

Wheel End, Includes Key Nos . 3-53 *1"-8 UNC x 6" Hex Bolt 84 *1" Hardened Washer 165 *1"-8 UNC Locknut 86 Bar Pin Shim 8 a 50131-000 0 .25" / 0 .12" Standard b 50130-000 0 .19" / 0 .19" Optional c 57026-000 0 .375" Optional flat shim 60961-712 Tie‑bar Bolster Springs and Progressive Load

Spring Service Kit, One Side, Includes two 64179-048 and one 60961-745 Service Kits

64179-048 **Tie‑bar Bolster Spring Service Kit, 2 Bolsters with 1 Wear Plate, Includes Key Nos . 7, 9-13

64179-049 **Bolster Spring Service Kit, 2 Bolsters with 1 Wear Plate, Includes Key Nos . 8, 12-13

7 *Tie-bar Bolster Spring 88 *Bolster Spring 89 60818-003 ½"-13 UNC x 10" Flange Bolt for Tie-bar 410 60819-000 ½"-13 UNC Flange Nut for Tie-bar 411 65742-000 Tie-bar Bolster Spring Spacer 412 60819-000 ½"-13 UNC Flange Nut 3213 64890-000L Wear Plate, Replaces 60498-001 and 60498-002 4 Saddle Assembly Service Kit, Tandem Set, 57974-051 HAULMAAX 40K, Includes Key No . 14a and

Kit No . 57974-048 57974-050 HAULMAAX 46K, Includes Key No . 14b and

Kit No . 57974-049 Saddle Assembly Fastener Kit, Tandem Set, 57974-048 HAULMAAX 40K, Includes Key Nos .

12, 22-24, 26-27, 36-37, 41-42 57974-049 HAULMAAX 46K, Includes Key Nos .

9-12, 22-24, 26-27, 36-37, 41-4214 ***Saddle Assembly, Vehicles built after 01/13/03 2 a 64642-000 HAULMAAX 40K b 64643-000 HAULMAAX 46K15 ***Outboard Frame Bracket, see Page 11 2

Vehicles built after 01/12/ 0316 Inboard Frame Bracket, see Page 11 217 78441-000 Inboard Frame Bracket Shim, (46K, if equipped, 2

International Truck Only) 18 32043-004 5⁄8"-11 UNC x 2¼" Hex Bolt 12 ******M16 Hex Bolt19 22962-004 5⁄8" Hardened Washer 24 ******M16 Hardened Washer20 47764-000 5⁄8"-11 UNC Locknut 12 ******M16 Locknut

21 Inboard Spacer (if equipped) As Req . 60618-001 1⁄8" Thick 60618-002 3⁄8" Thick Outboard Frame Bracket to Saddle Assembly

Fastener Kit, Includes Key Nos . 22-24 64179-038 Tandem Set 64179-039 One Side22 *M20 x 2 .5-6G x 65 mm Hex Bolt 2023 *M20 Hardened Washer 4024 *M20 x 2½-6H Locknut 20 57974-046 Contact Plate Service Kit, One Side,

Includes Key Nos . 25-2725 59191-000 Load Spring Contact Plate 226 *5⁄8"-11 UNC x 1½" Flange Bolt 8

for Vehicles built after 11/07 ****Replaces 60818-001

27 *5⁄8"-11 UNC Flange Nut 8 for Vehicles built after 11/07 ****Replaces 60819-000

28 ****Load Spring Contact Plate Spacer 8 for Vehicles built prior to 11/07

29 60791-000 Load Spring Shim ¼" Thickness 4 Quantity may vary for vehicles built prior to

07/15/14 equipped with Auxiliary Load Spring30 60818-002 ½"-13 UNC x 2¼" Flange Bolt 431 60819-000 ½"-13 UNC Flange Nut 4 64179-028 Rebound Strap Service Kit, One Side, Includes Key Nos . 32-33, 36-3932 *Rebound Strap 233 *Rebound Clip 234 60613-000 Rebound Support Angle 235 59384-000 Load Spring Bracket 236 60818-002 ½"-13 UNC x 2¼" Flange Bolt 437 60819-000 ½"-13 UNC Flange Nut 438 21867-007 ¾"-16 UNF x 6" Hex Bolt 239 30191-000 ¾"-16 UNF Locknut 2 Progressive Load Spring Service Kits

for vehicles built after 07/15/14 60961-745 One Side, Includes Key Nos . 40a, 41-42 60961-747 Tandem Set, Includes Key Nos . 40a, 41-42

• Also use as a conversion kit for vehicles built prior to 07/15/14

60961-746 Weight Bias Kit with Shims, Includes Key Nos . 29-31, 40a,b, 41-42, Replaces 65902-004

64179-004 Auxiliary Load Spring Service Kit, One Side, for vehicles built prior to 07/15/14

Includes Key Nos . 40b, 41-4240 Load Spring 2 a *Progressive b *Auxiliary41 *½"-13 UNC x 2¼" Flange Bolt 642 *½"-13 UNC Flange Nut 643 60874-000 Load Spring Spacer 2 Single Shock Absorber Service Kit,

(if equipped) Includes Key Nos . 44-47 64178-005 16½" Saddle Height 64178-006 17½" / 18½" Saddle Height Aftermarket Shock Absorber Kit for vehicles built

with equalizing beams without welded shock absorber mounts, see Page 13

44 Shock Absorber Assembly (if equipped) 4 60680-004L 16½" Saddle Height (see Figure 4-2) 60680-005L 17½" / 18½" Saddle Height (see Figure 4-2)45 32043-005 5⁄8"-11 UNC x 4¼" Hex Bolt (if equipped) 446 22962-004 5⁄8" Hardened Washer (if equipped) 847 47764-000 5⁄8"-11 UNC Locknut (if equipped) 448 60304-000 Upper Shock Bracket (if equipped) 4

Parts List 10 17730-244


49 One-piece Longitudinal Torque Rod Assembly, Straddle / Straddle

ULTRA ROD®, Includes Key No . 51a 62000-XXX Front, Specify Length in mm 1 62001-XXX Rear, Specify Length in mm 1 ULTRA ROD® PLUS™, Includes Key No . 51b 72000-XXX Front, Specify Length in mm 1 72001-XXX Rear, Specify Length in mm 1 82XX-XXXX-XXX *******TRAAX ROD™, Specify Length in mm 150 *****One-piece Transverse Torque Rod Assembly, 2

Straddle / Taper, Specify Length in mm 62350-XXX ULTRA ROD, Includes Key Nos . 51a-52a 72350-XXX ULTRA ROD PLUS, Includes Key Nos . 51b-52b 92350-XXX XTRB, Includes Key Nos . 51c-52c 82XX-XXXX-XXX *******TRAAX ROD51 Straddle Bushing 4 a 47691-000L ULTRA ROD b 64400-002L ULTRA ROD PLUS c 66649-002L XTRB

52 Taper Bushing 2 a 64697-000L ULTRA ROD b 64400-004L ULTRA ROD PLUS c 66649-004L XTRB Optional Two‑Piece Torque Rod Assembly with

Bushings Service Kit 60218-000 ULTRA ROD Straddle / Straddle 60215-000 ULTRA ROD Straddle / Taper 65781-000 ULTRA ROD PLUS Straddle / Taper 65781-001 XTRB Straddle / Straddle 65781-002 XTRB Straddle / Taper53 22186-000 Torque Rod Frame Bracket 254 45045-003 Back-up Plate (for Torque Rod) 255 49689-000L Torque Rod Shim As Req . 70867-001 P-80 Lubricant - 10 ml (Not Shown) per Bushing 1

FIGURE 4‑1 FIGURE 4‑2

NOTES:

* Item included in kit / assembly only, part not sold separately .

** HAULMAAX 46K suspensions must be serviced with the new tie-bar bolster spring Kit No . 64179-048 . All HAULMAAX 40K suspensions can be serviced using the existing bolster springs Kit No . 64179-049 or if preferred a Tie-bar Bolster Spring Kit No . 64179-048 . Refer to Hendrickson Technical Bulletin Literature No . SEU-0225 for more information .

*** For vehicles built prior to January 2003 it will be necessary to replace the saddle assembly with the current production saddle assembly and corresponding outboard frame bracket .

**** For vehicles built prior to November 2007, Kit No . 57974-046 is required when replacing the load spring contact plate or equalizing beam .

***** Transverse torque rods are mandatory for the HAULMAAX suspensions regardless of axle spacing, see Literature No . 59310-004 and 59310-058 for more information .

****** Not supplied by Hendrickson, used for reference only . Refer to vehicle manufacturer for more information . Hendrickson is not responsible for components supplied by vehicle manufacturer .

******* TRAAX RODs are non-rebushable . The entire torque rod assembly must be replaced .

Hendrickson HAULMAAX / HN Gauge can be obtained online at www .hendrickson-intil .com/Litform

• Literature number 48422-546 – Bolster Spring

• Literature number 48422-590 – Progressive Load Spring

To obtain a new Hendrickson HAULMAAX decal, No . 60905-002, contact Hendrickson .



17730-244 11 Parts List


■ Outboard • Inboard Frame Bracket Selection Guides

Key No. 15 Outboard Frame Bracket — Vehicles built after 01/13/03

Vehicle Manufacturer

Frame Width

Saddle Height = Dim. A in Figure 4‑2

16½" 17½" 18½" 20¼" 22½" 25½"

Autocar

34"

64595-611 64595-612 64595-613

CCC64595-801

replaces 64595-001

Freightliner 34 .3" - 34 .5" 64636-001 64636-002 64636-003

GM 34 .75" 64595-701

International Truck34 .12" - 34 .25" 64595-101 64595-105 64595-107

34 .68" - 34 .94" 64595-104 64595-114 64595-106 64595-108 64595-110

Mack33 .5" 64595-301 64595-302 64595-303

34 .3" 64595-307

Oshkosh34"

64595-003

Paccar64595-001 64595-002 64595-003 64595-105

34 .75" 64595-004 64595-005 64595-006

Volvo 33 .5" 64595-301

Western Star 34" 64595-001 64595-002 64595-003

Key No. 16 Inboard Frame Bracket

Vehicle Manufacturer

Frame Width

Equalizing Beam Length

Saddle Height = Dim. A in Figure 4‑2

16½" 17½" 18½" 20¼" 22½" 25½"

Autocar34"

All

60617-601 60617-602 60617-603

CCC 65078-001 65078-002 65078-003

Freightliner 34 .3"-34 .5" 60617-501 60617-502 60617-503

GM 34 .75" 60617-701

International Truck 34 .12" - 34 .25"34 .68" - 34 .94" 60617-101 60617-104 60617-103 69681-000

International Truck with shim 34 .5" 60617-201

Oshkosh 34" 65078-003

Paccar with liner 34", 34 .75"67545-001

replaces 65078-001

67545-002 replaces

65078-00267545-003

replaces 65078-003

Paccar without liner 34", 34 .75" 65079-001 65079-002 65079-003

Western Star 34" 60617-501 60617-502 60617-503

Mack 33 .5", 34 .3"52", 60" 64988-311

54" 64988-301

Volvo 33 .5"54" 64988-302

52", 60", 72 .5" 64988-312

Parts List 12 17730-244


■ Production Dual Rebound Straps – Outrigger Applications

Saddle Assembly Service Kits, One Side, 34013-335 HAULMAAX 40K, Includes Key No . 1 and

Kit No . 34013-336 34013-337 HAULMAAX 46K, Includes Key No . 1 and

Kit No . 34013-338 Saddle Assembly Fastener Kits, One Side, 34013-336 HAULMAAX 40K, Includes Key Nos .

5-6, 11-12, 15-16 (Refer to Page 9 for more information on Key Nos . 12, 22-24)

34013-338 HAULMAAX 46K, Includes Key Nos . 5-6, 11-12, 15-16 (Refer to Page 9 for more information on Key Nos . 9-12, 22-24)

1 79564-000 Saddle Assembly, Vehicles built with 2 Dual Rebound Straps

2 60818-001 ½"-13 UNC x 1½" Flange Bolt 43 60818-002 ½"-13 UNC Flange Nut 4 34013-339 Contact Plate Service Kit, One Side,

Includes Key Nos 4-64 59191-004 Load Spring Contact Plate 25 67290-001 5⁄8"-11 UNC x 1½" Flange Bolt 86 67291-000 5⁄8"-11 UNC Flange Nut 8

7 60874-000 313⁄16" Load Spring Spacer 28 60874-001 3¾" Load Spring Spacer 2 34013-340 Rebound Strap Service Kit, One Side,

Includes Key Nos . 9-149 *Rebound Strap 410 *Rebound Clip 411 60818-002 ½"-13 UNC x 2¼" Flange Bolt 812 60819-000 ½"-13 UNC Flange Nut 8 13 21867-026 ¾"-16 UNF x 5½" Bolt 414 30191-000 ¾"-16 UNF Locknut 4 34013-341 Progressive Load Spring Service Kit, One Side, Includes Key Nos . 15-1715 60818-002 ½"-13 UNC x 2¼" Flange Bolt 616 60819-000 ½"-13 UNC Flange Nut 6 17 *Progressive Load Spring 218 59384-005 Load Spring Bracket 219 60791-000 Load Spring Shim ¼" Thickness 420 60818-002 ½"-13 UNC x 2¼" Flange Bolt 421 60819-000 ½"-13 UNC Flange Nut 4



17730-244 13 Parts List


■ Aftermarket Service Kits AFTERMARKET DUAL REBOUND STRAP ENHANCEMENT KIT FOR OUTRIGGER APPLICATIONS

KIT KEY NO. PART NO. DESCRIPTION QTY.

64179-046 Rebound Strap Enhancement with Bolster Springs Tandem Set, Includes Key Nos . 1-23

64179-045 Rebound Strap Enhancement Tandem Set, Includes Key Nos . 1-18

1 21867-007 ¾"-16 UNF x 6" Bolt 42 30191-000 ¾"-16 UNF Locknut 43 22962-001 ¾" Hardened Washer 44 50764-016 ¾"-10 UNC x 4" Bolt 45 66137-000 ¾"-10 UNC Flange Locknut 46 60818-002 ½"-13 UNC x 2¼" Flange Bolt (Not Shown) 47 24531-009 ½"-13 UNC x 4" Bolt 128 24531-014 ½"-13 UNC x 5" Bolt 29 60819-000 ½"-13 UNC Flange Nut 1810 22962-011 ½" Hardened Washer 1411 67290-001 5⁄8"-11 UNC x 1½" Flange Bolt 812 67291-000 5⁄8"-11 UNC Flange Nut 813 57878-017 Rebound Strap 414 59191-002 Load Spring Contact Plate 215 60612-000 Rebound Clip 216 60874-001 Load Spring Spacer (Not Shown) 217 68851-001 Inboard Rebound Support Block (Not Shown) 218 69026-000 Outboard Rebound Support Block 219 *Tie-bar Bolster Spring 820 65742-000 Bolster Spring Spacer 421 60818-003 ½"-13 UNC x 10" Flange Bolt 422 60819-000 ½"-13 UNC Flange Nut 3623 64890-000 Wear Plate 4

AFTERMARKET SHOCK ABSORBER SERVICE KITS

KIT KEY NO. PART NO. DESCRIPTION QTY.

Shock Absorber Service Kit, Tandem Set 64178-003 16½" Saddle Height,

Includes Key Nos . 1a, 2a-b, 3-9 64178-004 17½"/18½" Saddle Height,

Includes Key Nos . 1b, 2a-b, 3-9 64178-009 16½" Saddle Height - Mack Only,

Includes Key Nos . 1c, 2c, 3-91 Shock Absorber Assembly 4 a 60680-004L 16½" Saddle Height b 60680-005L 17½"/18½" Saddle Height c 60680-006L 16½" Saddle Height – Mack2 Lower Shock Bracket a 64148-001 Front 2 b 64148-002 Rear (Not Shown) 2 c 64835-000 Mack Only, Front and Rear (Not Shown) 43 48941-006 1"-8 UNC x 7" Hex Bolt, Replaces 48941-001 44 22962-008 1" Hardened Washer 125 48942-000 1"-8 UNC Locknut 4 6 64146-000 Upper Shock Bracket 47 32043-005 5⁄8"-11 UNC x 4½" Hex Bolt 48 22962-004 5⁄8" Hardened Washer 89 47764-000 5⁄8"-11 UNC Locknut 4

Special Tools 14 17730-244


SECTION 5

Special ToolsBAR PIN END BUSHING TOOLS

INSTALLATION TOOL

Hendrickson Part No. 66086‑103OTC Part No. 1757 Visit otctools .com

Use with the equalizing beam removed from the truck, and in conjunction with OTC No . 51100 press plate and a 100 ton hydraulic shop press .

REMOVAL TOOLS



This shop made tool is made from cold rolled steel or equivalent . The drawing is for reference only . Hendrickson does not supply this tool .

17730-244 15 Special Tools


TORQUE ROD BUSHING FUNNEL TOOLS

ULTRA ROD Hendrickson Part No. 66086‑001L

ULTRA ROD PLUS Hendrickson Part No. 66086‑000L

These shop made tools are designed for the torque rod bushings . Bushing tools are to be made from cold rolled steel or equivalent . Drawing is for reference only . Hendrickson does not supply this tools .

ULTRA ROD BUSHING ULTRA ROD PLUS AND XTRB BUSHING


Preventive Maintenance 16 17730-244

SECTION 6

Preventive MaintenanceFollowing appropriate inspection procedures is important to help ensure the proper maintenance and operation of the suspension system and component parts . Hendrickson recommends the HAULMAAX heavy-duty rear suspension be inspected at pre-delivery, the first 1,000 miles and at the regular preventive maintenance intervals . Off-highway and severe service operating condi-tions require more frequent inspections than on-highway service operation . Inspection must include the following items and other components referenced in this section .

PROGRESSIVE LOAD SPRING PRE‑DELIVERY INSPECTION THE HAULMAAX SUSPENSION MUST BE EQUIPPED WITH AT LEAST ONE (1) LOAD SPRING SHIM ON

EACH SIDE OF THE SUSPENSION . FAILURE TO DO SO CAN CAUSE PREMATURE COMPONENT WEAR, EQUALIZING BEAM MISALIGNMENT, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

Check for proper use of progressive load spring shims (minimum of one (1) shim and maximum of four (4) shims), which is dependent on the following criteria:

■ For applications where increasing stability is required, equally install additional shims per side . This may eliminate any gap between the load spring and the top load spring shim which is acceptable . Refer to the Alignment & Adjustments Section of this publication .

HENDRICKSON RECOMMENDED INSPECTION INTERVALS

PRE‑DELIVERY INSPECTION

FIRST IN‑SERVICE INSPECTION

PREVENTIVE MAINTENANCE

Inspect load springs, rebound straps, wear plates and bolster springs / tie-bar bolster springs .

Within the first 100 miles (160 km)

Within the first 1,000 miles

(1,600 km) or 100 hours

Every 3 months / 600 hours

Inspect the equalizing beam end connections

Every 6 Months / 1200 Hours or 25,000 miles (40,000 km)

Visually inspect for proper assembly and function . Check for all of the following and replace components as necessary .

• Signs of unusual movement, loose or missing components

• Signs of abrasive or adverse contact with other components

• Damaged, bent or cracked parts

Every 12 Months / 2400 Hours

Inspect fasteners for proper torque as recommended in the Torque Specification Section of this publication with special attention to the following suspension connections:

• Saddle to the outboard frame bracket connection

• Equalizing beam end connections

• Inboard frame bracket to the cross member connections

• Load spring contact plate to equalizing beam assembly connections

Verify the lateral alignment of axles are within the vehicle manufacturer’s tolerances


17730-244 17 Preventive Maintenance

COMPONENT INSPECTIONFollowing the appropriate inspection procedures is important to help ensure the proper mainte-nance and operation of the HAULMAAX suspension system and component parts . Look for bent or cracked parts . Replace all worn or damaged parts .

■ Equalizing beam assembly — Check the overall condition of the equalizing beam for dents, dings, or other damage . Check the equalizing beam end connections for tearing or extreme bulging . Check for any metal-to-metal contact in the bushed joints, see Equalizing Beam End Connection Section of this publication .

■ Fasteners — Look for any loose or damaged fasteners on the entire suspension . Make sure all fasteners are tightened to a torque value within the specified torque range . See recommended torque specifications for Hendrickson supplied fasteners in Torque Specification Section of this publication . For fasteners not supplied by Hendrickson, see vehicle manufacturer . Use a calibrated torque wrench to check torque in the tightening direction . As soon as the fastener starts to move, record the torque . Correct the torque if necessary .

NOTE Hendrickson recommends the use of Grade 8 bolts, hardened flat washers, and Grade C locknuts . Washers are not necessary when flange head fasteners are used .

■ Frame brackets — Look for any signs of wear and damage . ■ Bolster springs / tie‑bar bolster springs, load springs, and rebound straps — See the Bolster

Springs, Load Springs – Progressive or Auxiliary, and Rebound Straps in this section . ■ Saddle assembly — Check all attaching fasteners for proper torque . Visually inspect the

saddle for signs of movement on the frame rail or damage . Inspect the area around the saddle gussets for cracks .

■ Shock absorbers (if equipped) — Look for any signs of dents or leakage, see Shock Absorbers in this section .

■ Torque rods — All torque rods must be inspected every six (6) months for looseness, torn or shredded rubber, bushing walk-out, and for proper fastener torque . If there is metal-to-metal contact in the bushing joint, this is a sign of excessive bushing wear and the bushing needs to be replaced .

■ Wear and damage — Inspect all parts of the suspension for wear and damage . Look for bent or cracked parts .

■ Wear plates — Look for any signs of wear and damage, see Wear Plates in this section .

See vehicle manufacturer’s applicable publications for other preventive maintenance requirements .

LONGITUDINAL AND TRANSVERSE TORQUE RODS THE HAULMAAX SUSPENSION INCORPORATES TRANSVERSE RODS FOR VEHICLE STABILITY . IF THESE

COMPONENTS ARE DISCONNECTED OR ARE NON-FUNCTIONAL THE VEHICLE SHOULD NOT BE OPERATED . FAILURE TO DO SO CAN RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE TIRE CONTACT WITH THE FRAME . OPERATING A VEHICLE WITH NON-FUNCTIONAL TRANSVERSE TORQUE RODS CAN RESULT IN ADVERSE VEHICLE HANDLING, SEVERE PERSONAL INJURY, AND PREMATURE COMPONENT DAMAGE .

All torque rods need to be inspected for looseness by one of the following methods . ■ Method 1 — Procedure for on‑highway tractor applications ONLY with brakes applied, slowly

rock the empty vehicle with power while a mechanic visually checks the action at both ends . ■ Method 2 — with the vehicle shut down, a lever check can be made with a long pry bar

placed under each torque rod end and pressure applied .

NOTE Hendrickson Suspension recommends Grade 8 bolts, hardened flat washer and Grade C locknuts be used for all straddle mount torque rod attachments .



Visually inspect torque rod bushings for torn or shredded rubber, inspect for bent, cracked or bro-ken torque rods and for end hubs that have an elongated oval shape . The torque rod and or torque rod bushings will require replacement if any of these conditions are encountered .

Torque rod length is determined by the vehicle manufacturer for optimum drive line angles . The longitudinal torque rods control these angles and also absorb acceleration and braking forces . The mounting brackets at the axle ends of the torque rods are furnished and welded into position on the axle housings by vehicle manufacturer or the axle manufacturer . A two-piece torque rod is also available to cut and weld to the desired length, see Hendrickson publication 45745-148 .

FIGURE 6‑1

Straddle mount torque rod end attaching fasteners are fur-nished by the vehicle manufacturer . It is important that the tightening torque of the locknuts be checked during preven-tive maintenance service . Follow the vehicle manufacturer’s specifications for torque values .

The longitudinal rod is straddle/straddle mount, and the transverse rod is straddle mount / taper pin mount, as shown in Figure 6-1 .

Whether the torque rod is equipped with straddle or taper pin bushings, (see Figure 6-1) they can be replaced by pressing out the worn bushing and installing a new genuine Hendrickson bushing . Refer to the Torque Rod Bushings Component Replacement Section of this publication for replacement instructions .

BOLSTER SPRINGSInspect all four (4) bolster springs on a periodic basis, see Figure 6-2 . Actual bolster spring / tie-bar bolster spring service condition and performance may vary depending upon suspension and vehicle configuration, operation, service and other factors .

INSPECTIONThe following inspection guidelines are intended to assist vehicle operators and maintenance personnel in examining the bolster springs / tie-bar bolster springs and determining when replacements may be needed . FIGURE 6‑2

In the event one (1) bolster spring / tie-bar bolster spring on one (1) equalizing beam assembly shows signs of damage or excessive wear, Hendrickson recommends that both bol-ster springs installed on that equalizing beam assembly be replaced . When the bolster springs are replaced on one side only, the vehicle may lean slightly, see Figure 6-2 . The new bol-ster springs will tend to settle to some degree, and return the vehicle to its original condition . The following procedure is rec-ommended for proper inspection .

1 . Chock the FRONT wheels to prevent movement of the vehi-cle during inspection of the suspension .

2 . Raise the rear of vehicle approximately 4"-5" (just prior to lifting wheels off ground), and sup-port with stands .

3 . Inspect all bolster springs using the following criteria . If cuts, splits, or bonding separation are detected in the rubber, measure the depth of the damaged area using a six-inch machinist scale to determine if replacement is required .

■ Bent, burred or overhanging edges of the bolster spring metal plates may occur due to mishandling in service . If the rubber is not trapped, and there are no sharp metal edges in contact with the free surface of the rubber, this condition is acceptable .



■ Creases formed by folding of the rubber surface under load are acceptable . These creases appear as stripes on the surface, polished by wear or covered with tacky rubber .

■ Minor oil and grease contamination in the rubber due to vehicle operation is acceptable . A slight change in shape of the rubber due to permanent set should not be mistaken for oil and grease contamination . Certain softening of the rubber surface is acceptable . However, unacceptable swelling due to contamination will require bolster spring replacement . In the unloaded condition, if the bolster spring rubber is swollen beyond the edge of the metal plates, then tie-bar bolster spring replacement is necessary .

■ A Hendrickson HAULMAAX • HN gauge (Lit . No . 48422-546) is available to help measure the bolster spring for cut or splits and bonding separation, see Figure 6-3 .

FIGURE 6‑3 HAULMAAX • HN Gauge – Lit . No . 48422-546 FIGURE 6‑4

■ Cuts or Splits in the rubber of over 1 .0" in length and an average depth of 3⁄8" are not acceptable and require bolster spring replacement . In particular, look for signs of cuts or splits in the rubber at points indicated in Figure 6-4 as “///////” .

■ Bonding separation of the rubber from a bonded metal surface to a depth of up to ½" is acceptable . If any bonding separation is more than ½" deep, both bolster springs should be replaced on the affected side of the vehicle (see Figure 6-4) . An unloaded bolster spring may be inspected for any bonding separation by measuring at points indicated in Figure 6-4 as “/////// ” . Any thin film or other residual rubber material on the metal plates resulting from the molding process may be ignored during inspection .

LOAD SPRINGS – PROGRESSIVE OR AUXILIARY A visual inspection of the progressive load spring / auxiliary load spring, see Figure 6-5, is required every three (3) months . If the load spring is damaged or is less than the minimum unloaded height of 3", replace as outlined in the Load Springs – Progressive or Auxiliary Component Replacement Section of this publication .

■ A Hendrickson HAULMAAX Gauge (Lit . No . 48422-590) is available to help measure the load spring minimum height, to be used with an 3⁄8" extension, see Figure 6-6 .

FIGURE 6‑5 FIGURE 6‑6 HAULMAAX Gauge – Lit . No . 48422-590

Auxiliary Load SpringProgressive Load Spring



■ Progressive load spring — Unloaded normal height is 4¼", if the height of an unloaded progressive load spring decreases to 3 .0" or less, replacement is required, see Figure 6-7 .

■ Auxiliary load spring — Unloaded normal height is 33⁄8", if the height of an unloaded auxil-iary load spring decreases to 3 .0" or less, replacement is required, see Figure 6-8 .


WEAR PLATESThe wear plate is a formed stainless steel component located between the bolster springs / tie-bar bolster springs and the equalizing beam, see Figure 6-9 . The function of the wear plate is to prevent chafing of the equalizing beam by the bolster springs / tie-bar bolster springs during certain operational maneuvers . If the wear plate is cracked or worn through, replace as outlined, see Bolster Springs in the Component Replacement Section of this publication .

NOTE Vehicles manufactured from November 2003 through November 2007 require the installation of load spring contact plate spacers between the contact plate and the equalizing beam, see Figure 6-9 .

FIGURE 6‑9

REBOUND STRAPSThe rebound strap helps prevent the overextension of the bolster springs / tie-bar bolster springs during normal vehicle operation . If the rebound strap is torn, frayed or not intact, replace as out-lined in the Standard Rebound Straps or the Production or Aftermarket Dual Rebound Straps Component Replacement Section of this publication .

EQUALIZING BEAM END CONNECTION NOTE The equalizing beam end connections require that the fasteners are tightened to torque specifi-

cations to maintain the clamp load of the axle bracket legs to the bar pin . All bushing motion is accommodated by rubber deflection .

An inspection of the equalizing beam end connections is necessary when a vehicle is in the shop for major repair work or every six (6) months, whichever comes first . Periodic visual inspection by the driver and service personnel is also recommended . Off-highway and severe service operating conditions require more frequent inspections than on-highway service operation .



VISUAL INSPECTION1 . Chock the wheels .

2 . Visually inspect suspension components for signs of movement or excessive wear . ■ Inspect alignment shims in equalizing beam end for looseness . Lightly tap on the align-

ment shims to see if they can be moved . If the movement is detected, refer to the bar pin fastener re-torque in the Equalizing Beam Component Replacement Section .

■ Inspect equalizing beam end connection for signs of excessive wear or looseness .

SERVICE HINT An equalizing beam end connection, which is visibly cleaner than the other connections, may indicate a loose connection .

■ Look for worn, frayed or distorted rubber in the bar pin beam end bushing, see Figure 6-10 . ■ Look for the equalizing beam to be lower in the axle bracket, see Figure 6-10 . ■ If the bar pin beam end bushing is visually offset a floor jack test should be performed .

See Physical Inspection .

FIGURE 6‑10

PHYSICAL INSPECTION FIGURE 6‑11

NOTE The gap at each side of the visible rubber on the lower part of the bar pin end bushing is normal, see Figure 6-11, it is not an indication to replace the bushing . All rubber end bushings are in compression with the load bearing on the top side, the lower side of the rubber is slightly relieved, allowing the rubber to move inward, and a gap appears .

IF BAR PIN END BUSHING MOVEMENT OR LOOSENESS IS NOTED IN THE EQUALIZING BEAM END HUB, DO NOT OPERATE THE VEHICLE . REPLACE THE RUBBER END BUSHINGS AND ALL CONNECTING PARTS . THE ABOVE CONDITION CAN RESULT IN COSTLY REPAIR, DOWNTIME, POSSIBLE SEPARATION OF COMPONENTS, ADVERSE VEHICLE HANDLING, PROPERTY DAMAGE, OR PERSONAL INJURY .

1 . Place a floor jack under each beam end as shown . Raise the floor jack to check for movement in the connection or rubber components, see Figure 6-11 .



2 . If bar pin end bushing movement or looseness is detected in the equalizing beam end hub, replace the end bushings and all connecting parts . Refer to the Bar Pin End Bushing Component Replacement Section of this publication .

FIGURE 6‑12

3 . Check and record torque values, as received, for each 1" bar pin fastener, see Figure 6-12 . Ensure all fasteners are tightened to the following:

■ At the locknuts tighten to 525 ± 75 foot pounds torque or

■ At the bolt head tighten to 575 ± 75 foot pounds torque

4 . Recheck equalizing beam end connections for signs of looseness .

■ Inspect alignment shims in equalizing beam end for looseness . Lightly tap on the alignment shims to see if they can be moved . If the move-ment is detected, refer to the bar pin fastener re-torque in the Equalizing Beam Component Replacement Section .

■ Inspect equalizing beam end connection for signs of excessive wear or looseness .

NOTE An equalizing beam end connection that is visibly cleaner than the other connections may indi-cate a loose connection .

5 . If bar pin bushing looseness is still detected, DO NOT operate the vehicle . One or more components will require replacement, see Component Replacement Section of this publication .

AXLE BRACKETFIGURE 6‑13 FIGURE 6‑14

The axle brackets are furnished and welded into position by the vehicle or axle manufacturer . ■ Visual Inspection — when inspecting the equalizing beam end connection also inspect the

axle brackets for damage or cracks, see Figure 6-13 . Any axle bracket that is found damaged or cracked must be repaired or replaced .



■ Physical Inspection — When an equalizing beam is removed for repair, or an inspection of the equalizing beam end connection reveals movement:

■ Inspect the axle brackets for damage or cracks in the locations shown in Figures 6-13 and 6-14 . Any axle bracket that is found damaged or cracked must be repaired or replaced .

■ Measure the distance between the axle bracket legs for correct width, refer to Figures 6-13 and 6-14 for measurement location and dimensions . An axle bracket outside of the measurement range must be repaired or replaced .

Consult the vehicle manufacturer for inspection, component repair and replacement instructions .

BAR PIN END BUSHINGS FIGURE 6‑15

VISUAL INSPECTIONAn indication that the bar pin end bushing requires replacement when one or more of the following con-ditions apply:

■ If the contact area, see Figure 6-15 (the flat face area where bar pin contacts the axle bracket) reveal signs of excessive wear . A bar pin thickness measurement of less than 1 .874" (47 .59 mm) .

■ If the bar pin bolt holes bores reveal signs of elongation or wear, see Figure 6-15 .

BAR PIN SHIMSAn indication that the bar pin shims require replacement is when one or more of the following conditions apply:

■ Visual inspection of contact area on the shim reveals signs of excessive wear . ■ The thickness of any single leg on the shim, is less than the measurement shown in Figure

6-16, replacement of bar pin shim is required .FIGURE 6‑16

Original Thickness of

Shim Leg

Minimum Thickness Required

Part Number

1⁄8" (3 .2 mm) 0 .123" (3 .1 mm) 50131-000

3⁄16" (4 .8 mm) 0 .186" (4 .7 mm) 50130-000

¼" (6 .4 mm) 0 .248" (6 .3 mm) 50131-000

3⁄8" (9 .5 mm) 0 .371" (9 .4 mm) 57026-000



SHOCK ABSORBERS (if equipped)NOTE It is not necessary to replace shock absorbers in pairs if one (1) shock absorber requires

replacement .

Hendrickson uses a long service life, premium shock absorber on all HAULMAAX suspensions . When the shock absorber replacement is necessary, Hendrickson recommends that the shock absorbers be replaced with identical Hendrickson Genuine parts for servicing . Failure to do so will affect the suspension performance, durability, and will void any applicable warranty . See vehicle manufacturer’s applicable publications for other shock absorber inspection requirements .

Inspection of the shock absorber can be performed by doing a heat test, and a visual inspec-tion . For instructions on shock absorber replacement see the Component Replacement Section of this publication .

NOTE Tractor and Logging applications — Shock absorbers are mandatory in tractor and logging applications . The flexibility of the HAULMAAX suspension allows customers to specify the suspen-sion with or without shock absorbers . In many applications, the use of shock absorbers minimizes wheel hop and can improve ride and traction . Ride performance can be subjective and may be dependent on many factors beyond the suspension design, such as cab suspension, road condi-tions, body/auxiliary equipment, frame specifications, etc .

Based on testing and field experience, wheel hop conditions may exist in tractor and logging applications . Therefore, in order to help minimize wheel hop and improve ride performance, Hendrickson requires that HAULMAAX suspensions used in tractor and logging applications be ordered and operated with shock absorbers .

FIGURE 6‑17

HEAT TEST INSPECTION1 . Drive the vehicle at moderate speeds on rough

road for minimum of fifteen minutes .

DO NOT GRAB THE SHOCK ABSORBER AS IT COULD POSSIBLY BE HOT AND CAUSE PERSONAL INJURY .

2 . Use an infrared thermometer to check the tem-perature of the shock absorber . This can also be performed by carefully touching the shock absorber body below the dust cover . Touch the frame to get an ambient reference, see Figure 6-17 . A warm shock absorber is acceptable, a cold shock absorber should be replaced .

3 . To inspect for an internal failure, remove and shake the suspected shock absorber . Listen for the sound of metal parts rattling inside . Rattling of metal parts can indicate that the shock absorber has an internal failure and the shock absorber should be replaced .



VISUAL INSPECTIONLook for these potential problems, see Figure 6-18, when doing a visual inspection . Inspect the shock absorbers fully extended . Replace as necessary .

FIGURE 6‑18

LEAKING VS. MISTING SHOCK VISUAL INSPECTION FIGURE 6‑19

The inspection must not be conducted after driving in wet weather or a vehicle wash . The shock absorber needs to be free from water . Many shock absorbers are often misdiagnosed as failures . Misting is the process whereby very small amounts of shock absorber fluid evaporate at a high operating temperature through the upper seal of the shock absorber . When the “mist” reaches the cooler outside air, it condenses and forms a film on the outside of the shock absorber body . Misting is perfectly normal and necessary function of the shock absorber . The fluid which evaporates through the seal area helps to lubricate and prolong the life of the seal .

NOTE The HAULMAAX suspension is equipped with a premium seal on the shock absorber, however this seal will allow for misting to appear on the shock absorber body (mist-ing is not a leak and is considered acceptable) .

Inspect the shock absorber fully extended . A shock absorber that is truly leaking will show signs of fluid leaking in streams from the upper seal . These streams can easily be seen, underneath the main body (dust cover) of the shock absorber . Replace as necessary .

SHOCK ABSORBER VISUAL INSPECTION - UNACCEPTABLE CONDITIONS

Damaged upper or lower mount

Damaged upper or lower bushing

Damaged dust coverand / or shock body

Bent or dented shockabsorber

Improper intallationExample: washer (if equipped installed backwards


Alignment & Adjustments 26 17730-244

SECTION 7

Alignment & AdjustmentsThe points on the suspension that control alignment are:

■ The location of the frame hangers on the frame as installed by the vehicle manufacturer . ■ The location of the equalizing beam hangers on the axles as installed by the axle manu-

facturer or the truck manufacturer .

DRIVE AXLE ALIGNMENTProper alignment is essential for maximum ride quality, performance, and tire service life . The following recommended alignment procedure, should be performed if excessive or irregular tire wear is observed .

NOTE Proper vehicle alignment can only be achieved when all axles are aligned to the vehicle’s center-line and the steering axle’s caster, camber and toe-in settings are within specifications . If, however, axle alignment equipment is not available the alignment of the drive axles may be checked by performing the following steps .

FIGURE 7‑1

INSPECTION1 . Use a work bay with a level, flat surface .

2 . Relax the suspension by slowly mov-ing the vehicle back and forth several times in a straight line without using the brakes . This will slacken or loosen the suspension as the vehicle is posi-tioned . End with all wheels positioned straight ahead .

3 . DO NOT set the parking brake . Chock the FRONT wheels of the vehicle .

4 . Verify all suspension components are in good condition . Repair or replace any worn or damaged suspension components before proceeding with the alignment process .

5 . Ensure all drive axle tires are the same size .

6 . Securely clamp a six-foot piece of STRAIGHT bar stock or angle iron across the lower frame flange as shown in Figure 7-1 . Select a location for the bar stock or angle iron as far forward of the drive axle as possible where components will not interfere .

7 . Accurately square the bar stock or angle iron to the frame using a carpenter’s square .

8 . Using a measuring tape, measure from the straight edge to the forward face of the front drive axle arms on both sides of the vehicle as shown in Figure 7-1, A and B .

9 . Calculate the difference between measurements A and B .

a . If the front drive axle is within vehicle manufacturer’s specifications, proceed to check the rear drive axle (Step 11) .

b . If alignment of the front drive axle IS NOT within the vehicle manufacturer’s specifica-tions, then the alignment of this axle MUST be corrected BEFORE measuring the rear drive axle alignment (Step 11) . Correct the alignment of this axle by following the bar pin alignment instructions .


17730-244 27 Alignment & Adjustments

NOTE Since the remaining drive axle will be aligned relative to the front drive axle, it is essential that the front drive axle is aligned within the vehicle manufacturer’s specifications prior to the alignment of the remaining drive axle .

10 . Using a trammel bar, measure the distance from the spindle center of the front drive axle to the spindle center of the rear drive axle on both sides of the vehicle; see Figure 7-1, C and D .

11 . Calculate the difference between measurements C and D .

a . If the measurements are within the vehicle manufacturer’s specifications, then the rear drive axle alignment is acceptable .

b . If alignment of the rear drive axle IS NOT within the vehicle manufacturer’s specifications, then the alignment of this axle MUST be corrected . Correct the alignment of this axle by following the bar pin alignment instructions .

12 . Recheck measurements to confirm adjustments . Repeat Steps 9 through 11 until the correct alignment is achieved .

13 . When all drive axle alignments are within the vehicle manufacturer’s specifications then the alignment procedure is complete .

FIGURE 7‑2

LATERAL ALIGNMENT1 . Use a work bay with a level floor .

2 . Drive the vehicle slowly, straight ahead . Try to slacken or loosen the suspension as the vehicle is positioned . End with all wheels positioned straight ahead . Try to roll to a stop without the brakes being used . DO NOT set the parking brake .

3 . Chock the FRONT wheels of the vehicle .

4 . Measure from the outside of the frame rail to the rim flange of the inner tire . Record the measurement A and B, see Figure 7-2 .

5 . Measure the same distance on the opposite side of the same axle . Record the measurement C and D, see Figure 7-2 .

6 . Verify the lateral alignment is within the vehicle manu-facturer’s specifications . Adding or removing shims that are located between the transverse torque rod and frame rail will normally correct the lateral alignment .

■ A general rule of thumb is to use a shim with a thick-ness that is half of the difference between the two measurements .

EXAMPLE If the lateral alignment is out of specification by ¼" (6 mm), remove or install a 1⁄8" (3 mm) shim between the transverse torque rod and frame rail as needed . Refer to Longitudinal and Transverse Torque Rod Section in Preventive Maintenance Section of this publication .

NOTE Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts be used for all torque rod attachments .



BAR PIN WITH SHIMS ALIGNMENT FIGURE 7‑3

The alignment feature consists of specially designed, tightly tolerance steel shims which fill the 3⁄8" total gap between the bushing’s bar pin and the axle bracket legs . The gap must be filled by placing the shims on the bushing assembly in one of the positions shown in Figures 7-3 and 7-5 . Hendrickson has three (3) shim designs options for alignment, part number 50130-000 (provided), 50131-000 and 57026-000, see Figure 7-6 .

A BAR PIN SHIM MUST BE INSTALLED AT EACH BOLT LOCATION . THE SAME PART NUMBER SHIM IN THE SAME ORIENTATION MUST BE USED AT BOTH BOLT LOCATIONS ON ANY ONE (1) END BUSHING . DO NOT INSTALL OR STACK MORE THAN ONE (1) SHIM AT EACH BOLT LOCATION . USE GENUINE HENDRICKSON BAR PIN SHIMS, DO NOT USE STANDARD WASHERS . FAILURE TO FOLLOW THESE WARNINGS MAY RESULT IN IMPROPER VEHICLE ALIGNMENT, FRACTURE OF THE AXLE BRACKET OR BAR PIN WHICH COULD RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

ALIGNMENT ADJUSTMENT PROCEDURE FIGURE 7‑4

NOTE Computerized alignment equipment, such as a Hunter WT100 series, is the preferred method of measuring align-ment . Laser alignment equipment may be used, however, to calculate the shim thickness required the target offset must be converted to thrust angle, see alignment equip-ment manufacturer for procedures .

If alignment of the drive axles is required, as determined by an alignment inspection procedure, the following steps will need to be performed .

1 . Determine direction of axle thrust angle . Figure 7-4 illustrates the forward drive axle with a thrust angle to the left (-negative thrust) .

SERVICE HINT Axle movement is in the same direction as the increased shim thickness, see Figure 7-5 .

2 . To determine where to adjust shim thickness use mea-surement (A and B) for front drive axle or (C and D) for rear drive axle, see Figure 7-1 .

SERVICE HINT Axle adjustment will be on the side of the bar pin where shim thickness is increased . For example, to correct the axle thrust angle illustrated in Figure 7-4, shim thickness will need to be increased at the BACK of the bar pin (Location X) and / or the FRONT of the bar pin (Location Y) .

EACH EQUALIZING BEAM END BUSHING HAS ONE (1) INBOARD AND ONE (1) OUTBOARD ALIGNMENT SHIM, FOR A TOTAL OF FOUR (4) SETS OF TWO (2) ALIGNMENT SHIMS PER SUSPENSION . EACH SET OF ALIGNMENT SHIMS FOR A PARTICULAR BEAM END BUSHING MUST BE INSTALLED IN THE SAME ORIENTATION . SHIM ORIENTATION MAY DIFFER FOR EACH BEAM END BUSHING, SEE FIGURE 7-3 . FAILURE TO FOLLOW THESE WARNINGS MAY RESULT IN THE FRACTURE OF EITHER THE AXLE BRACKET OR BAR PIN WHICH COULD RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .



THE BAR PIN ALIGNMENT SHIM (PART NO . 50130-000) MUST BE INSTALLED WITH THE FOLDED EDGE FACING AWAY FROM THE BUSHING, SEE FIGURE 7-6 . FAILURE TO DO SO MAY RESULT IN SHIM DAMAGE, IMPROPER ALIGNMENT, DAMAGE OR FRACTURE OF THE AXLE BRACKET OR BAR PIN WHICH COULD RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

FIGURE 7‑5

FIGURE 7‑6



3 . Chock the wheels of the front axles to prevent vehicle movement during service .

4 . Raise the frame of the vehicle to remove the load from the suspension . Support the frame at this height .

5 . Support the equalizing beam and remove the fasteners from the end bushing where the bar pin alignment shim adjustment is being made .

6 . Adjust shim thickness to move the axle in the desired direction, see Figure 7-5 .

7 . Install new end bushing fasteners and tighten to: ■ At the locknut to 525 ± 75 foot pounds torque, or ■ At the bolt head to 575 ± 75 foot pounds torque

8 . Remove support and lower the vehicle .

9 . Verify the axles’ alignments are within the vehicle manufactures tolerance .

10 . Set brakes and remove wheel chocks .

LOAD SPRING SHIM EVALUATIONRide quality is subject to many influences in heavy-duty applications . They include, but are not limited to, body equipment, vehicle suspensions, cab suspension, terrain, chassis/frame specifica-tions, tires/wheels and wheelbase .

As shown in Figure 7-7, standard production vehicles specified with the HAULMAAX rear suspen-sion are typically equipped with:

■ AFTER July 2014 - progressive load spring equipped with two (2) load spring shims ■ PRIOR to July 2014 - auxiliary load spring equipped with three (3) load spring shims

NOTE With the exception of weight bias vehicles (refer to Hendrickson publication 59310-047), both sides of the vehicle must be equipped with the equal amount of load spring shims . Failure to do so will induce an undesirable vehicle lean .

FIGURE 7‑7

ADJUSTMENT NOTES1 . Both sides of the HAULMAAX suspension MUST have an equal number of load spring shims,

(shim part number 60791-000) in place .

THE HAULMAAX SUSPENSION MUST BE EQUIPPED WITH AT LEAST ONE (1) LOAD SPRING SHIM ON EACH SIDE OF THE SUSPENSION . FAILURE TO DO SO CAN CAUSE PREMATURE COMPONENT WEAR, EQUALIZING BEAM MISALIGNMENT, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

2 . The HAULMAAX suspension MUST be equipped with at least one (1) load spring shim per side .

3 . Some vehicles in the field may be equipped with more or less shims than the standard pro-duction assembly .



4 . For applications where increasing stability is required, equally install additional shims per side . This may eliminate any gap between the load spring and the top load spring shim which is acceptable .

■ For suspensions equipped with progressive load springs, use a maximum of four (4) load spring shims and a minimum of one (1) .

■ For suspensions equipped with auxiliary load springs, use a maximum of five (5) load spring shims and a minimum of one (1)

5 . After determining the proper amount of shims required, install or remove the shims as needed .

LOAD SPRING SHIM ADJUSTMENTThe unladen tandem weight with the body and equipment installed will influence the number of load spring shims necessary to achieve optimal ride quality and stability .

DISASSEMBLY FIGURE 7‑8


2 . Remove the fasteners that attach the load spring shims to the load spring contact plate, see Figure 7-8 .

SERVICE HINT If the load spring is in contact with the load spring shims, it will be necessary to raise the frame of the vehicle to service the load spring shims .

ASSEMBLY

THE HAULMAAX SUSPENSION MUST BE EQUIPPED WITH AT LEAST ONE (1) LOAD SPRING SHIM ON EACH SIDE OF THE SUSPENSION . FAILURE TO DO SO CAN CAUSE PREMATURE COMPONENT WEAR, EQUALIZING BEAM MISALIGNMENT, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

SERVICE HINT The number of exposed threads on the flange bolts varies with the amount of shims installed . Ensure there is at least three (3) threads exposed past the locknut .

1 . Install or remove load spring shims as needed: ■ For suspensions equipped with progressive load springs, use a maximum of four (4)

load spring shims and a minimum of one (1) ■ For suspensions equipped with auxiliary load springs, use a maximum of five (5) load

spring shims and a minimum of one (1)

2 . Install the fasteners that attach the load spring shims to the load spring contact plate and tighten to 98 ± 7 foot pounds torque, see Figure 7-8 .

3 . Lower the frame (If the vehicle was raised for disassembly) .

4 . Remove wheel chocks .


Component Replacement 32 17730-244

SECTION 8

Component Replacement

FASTENERSHendrickson recommends that when servicing a vehicle, replace all the removed fasteners with new equivalent fasteners . Maintain correct torque values at all times . Check torque values as specified . See Hendrickson’s Torque Specifications Section of this publication . If non-Hendrickson fasteners are used, follow torque specifications listed in the vehicle manufacturer’s service manual .

Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts . If flange head bolts and locknuts are not used, then hardened structural washers must be used under bolt heads and locknuts .

OUTBOARD FRAME BRACKETNOTE The outboard frame bracket on vehicles built prior to January 13, 2003 are no longer offered by

Hendrickson . See outboard frame bracket and saddle assembly conversion kits in the Parts List Section of this publication .



2 . Remove the fasteners from the outboard frame bracket and saddle assembly, see Figure 8-1 .

3 . Raise the frame enough to allow a ½" gap between the saddle assembly and the out-board frame bracket .

4 . Remove the frame fasteners, see manufac-turer’s guidelines .

5 . Remove the fasteners and inboard spacer (if equipped) from the outboard frame bracket and inboard frame bracket, see Figure 8-2 .

6 . Remove the outboard frame bracket .

ASSEMBLY1 . Mount the new outboard frame bracket to

the frame .

2 . Install the frame fasteners per the vehicle manufacturer’s .

3 . Install the fasteners into the outboard and inboard frame bracket assembly and inboard spacer (if equipped) and tighten to torque specifications, see Figure 8-2 .

■ 5⁄8" Locknuts, tighten to 200 ± 10 foot pounds torque ■ M16 locknuts, tighten to vehicle manufacturer’s specifications

4 . Completely lower the vehicle .

5 . Install the M20 fasteners into the saddle assembly and outboard frame bracket .

6 . Tighten the four (4) vertical fasteners first then the remaining six (6) M20 fasteners to 310 ± 30 foot pounds torque, see Figure 8-1 .



17730-244 33 Component Replacement

FIGURE 8‑2

INBOARD FRAME BRACKET

DISASSEMBLY1 . Chock the FRONT wheels of the vehicle .

NOTE When servicing the inboard frame bracket to vehicle cross member connection, it is important to remove all weight from the suspension to maintain the frame rail’s integrity and vertical position after service .

2 . Raise the rear of the vehicle until the suspension is fully extended with the tires completely off the ground . Support the frame at this height .

3 . Remove fasteners from the inboard frame bracket to the cross member . Remove inboard bracket shim if equipped .

4 . Remove fasteners from the inboard frame bracket to the outboard bracket . Remove inboard spacer if equipped .

5 . Remove the inboard frame bracket and inboard spacer (if equipped) .FIGURE 8‑3

ASSEMBLY1 . Mount the inboard frame bracket to the vehicle’s cross member and snug the fasteners . DO

NOT tighten at this time .

2 . Install the new inboard frame bracket to outboard frame bracket fasteners and inboard spacer (if equipped), and tighten to specifications, see Figure 8-2 .

■ 5⁄8" locknuts tighten to 200 ± 10 foot pounds torque ■ M16 locknuts tighten to vehicle manufacturer’s specifications



3 . Tighten the fasteners securing the inboard frame bracket to the vehicle manufacturer’s cross member, see Figure 8-3 .

■ 5⁄8" locknuts tighten to 200 ± 10 foot pounds torque ■ M16 locknuts tighten to vehicle manufacturer’s specifications

4 . Remove the frame supports .

5 . Remove the wheel chocks .

SADDLENOTE When changing both saddle assemblies, simultaneously perform the following replacement steps

on both sides of the vehicle . See Parts List Section of this publication for service kits available for saddle assembly replacement .

DISASSEMBLY

SERVICE HINT Replacement may be facilitated by servicing both sides of the suspension .


2 . From the inboard side of the saddles, remove and discard ½" upper fasteners from the rebound clip and load spring bracket, see Figure 8-4 . Remove the rebound clips .

3 . Loosen, DO NOT remove, the upper ½" flange head locknuts connecting the bolster springs / tie-bar bolster springs to the saddle assembly .

4 . Remove the lower ½" flange head locknuts that connects the bolster springs / tie-bar bolster springs to the equalizing beam .

5 . Remove and discard the upper shock absorber fasteners (if equipped), from the upper shock brackets . Push the shock absorbers down and clear of the upper shock brackets .

6 . Remove and discard the 5⁄8" or ½" fasteners from the load spring contact plate and equalizing beam, see Figure 8-4 .

SERVICE HINT Disconnecting the transverse torque rods will help with bolster spring alignment during disassem-bly and assembly .

7 . Disconnect the transverse torque rods from the frame, and take note of any shims that may be removed .

8 . Raise the rear of the vehicle frame just high enough to remove any contact between the load spring and the top of the load spring contact plate .

9 . Remove the load spring contact plates .

10 . Remove the three (3) ½" fasteners that attach the rebound support angle to the saddle . Remove the rebound support angle and load spring, see Figure 8-4 .

11 . Continue to raise the rear of the vehicle frame until the bolster springs just clear the equalizer beams . DO NOT over raise the frame .

12 . Support the rear of the vehicle frame at this height .

13 . Remove and discard the upper ½" flange head locknuts connecting the bolster springs to the saddle assembly, see Figure 8-5, and lower the bolster springs and wear plates back into the beam slots .

THE WEIGHT OF THE SADDLE IS APPROXIMATELY 70 POUNDS . CARE SHOULD BE TAKEN AT REMOVAL AND INSTALLATION TO PREVENT PERSONAL INJURY OR DAMAGE TO COMPONENTS .

14 . Remove and discard the M20 fasteners that attach the saddle to the outboard frame bracket, see Figure 8-6 .

15 . Remove the saddle from the vehicle .



FIGURE 8‑4

ASSEMBLY


1 . Mount the new saddle against the outboard frame bracket .

2 . Install the M20 fasteners into the saddle assembly and outboard frame bracket .

3 . Tighten the four (4) vertical fasteners first then the remaining six (6) M20 fasteners to 310 ± 30 foot pounds torque, see Figure 8-6 .

4 . Mount the load spring group: progressive / auxiliary load spring, load spring bracket, rebound support angle, and load spring spacer to the saddle by installing the ½" flange head bolts, see Figure 8-4 . Tighten to 98 ± 7 foot pounds torque .

5 . Mount the bolster springs / tie-bar bolster springs to the saddle and loosely install the ½" flange head locknuts on the bolster spring studs . DO NOT tighten at this time .

6 . If equipped with a tie-bar bolster spring, install the tie-bar bolt from the outboard side . Install the bolt through the outboard bolster mount, the tie-bar sleeve and the inboard bolster mount . Install the tie-bar locknut and tighten to 98 ± 7 foot pounds torque .

IF THE WEAR PLATES LOCATED BETWEEN THE EQUALIZING BEAM AND THE BOLSTER SPRINGS/TIE-BAR BOLSTER SPRINGS ARE DAMAGED, THEY MUST BE REPLACED . FAILURE TO DO SO CAN CAUSE DAMAGE TO MATING COMPONENTS .

7 . Verify the wear plates are on the lower bolster spring studs .

8 . Remove the frame supports and lower the vehicle, guiding the lower bolster spring studs into the wear plates and equalizing beam mounting slots . Ensure bolster spring studs sit at the bottom of the mounting slots on the equalizing beam, see Figure 8-5 .

9 . Install the lower ½" flange head locknuts on the bolster spring studs and tighten both upper and lower bolster spring fasteners to 98 ± 7 foot pounds torque .

10 . Mount the load spring contact plate on the equalizing beam by installing the fasteners . Tighten to 98 ± 7 foot pounds torque, see Figure 8-7 .




FIGURE 8‑7

11 . Lower the vehicle .

12 . Install the shock absorbers (if equipped) into the upper shock bracket and install the fasten-ers, tighten to 160 ± 10 foot pounds torque .

13 . Reattach the transverse torque rods to the frame, ensuring the shims are properly installed . Tighten to vehicle manufacturer’s specification .

14 . Mount the rebound clip and upper rebound strap to load spring bracket by installing the ½" flange fasteners and tighten to 98 ± 7 foot pounds torque, see Figure 8-4 .




LOAD SPRINGS – PROGRESSIVE OR AUXILIARYNOTE Hendrickson load spring service kits are available for the HAULMAAX suspension, refer to the

Parts List Section of this publication . There is also a service kit available to help adjust for vehicle side-to-side vehicle weight bias found with particular types of vehicle bodies or vehicle-mounted equipment used in certain applications (including, but not limited to, side-loading refuse and well driller) . Refer to Hendrickson Assembly Instructions 59310-047 for more information .

NOTE Use Kit No . 60961-747 when converting from the auxiliary load springs to the progressive load springs . The instructions are the same as below with the exception that it is necessary to remove one (1) load spring shim from each side of the suspension . The conversion requires both sides of the tandem to be replaced with the progressive load springs .

DISASSEMBLY

SERVICE HINT Tire removal is not necessary for the replacement of the load spring .


2 . Production Dual Strap only — Remove the OUTBOARD and INBOARD rebound clips, and fasteners . Lower rebound straps out of the way .

3 . Remove the three (3) ½" flange head fasteners from the saddle, progressive / auxiliary load spring, load spring bracket, and load spring spacer(s) .

4 . Raise the frame slightly to create a gap between the load spring and load spring shims, see Figure 8-7 .

5 . Remove the progressive / auxiliary load spring from the load spring bracket, see Figures 8-8 and 8-9 .


INSPECTION1 . Inspect load spring shims and any mating components for damage . Replace as necessary .

2 . Inspect the load spring bracket, rebound support angle (if equipped), rebound clip(s), and rebound strap(s) for damage . Replace as necessary .



ASSEMBLY1 . Install the new progressive / auxiliary load spring onto the load spring bracket .

2 . Mount the new load spring group (progressive / auxiliary load spring, load spring bracket, rebound support angle and load spring spacer) to the saddle by installing the ½" flange bolts to the through the load spring bracket to the saddle, see Figures 8-8 and 8-9 .

3 . Locate the locknuts on top of the saddle to prevent interference with equalizing beam assem-bly and tighten to 98 ± 7 foot pounds torque .

4 . Lower the frame .

5 . For Production Dual Strap only — Install the OUTBOARD and INBOARD rebound clips, fasten-ers, and rebound straps . Tighten fasteners to 98 ± 7 foot pounds torque .


STANDARD REBOUND STRAPS FIGURE 8‑10

NOTE Hendrickson recommends replacement of all rebound straps if only one requires replacement .

NOTE Hendrickson Rebound Strap Enhancement Kit No . 64179-045 is available for outrigger applications for HAULMAAX 40K•46K rear sus-pensions, to be used on as needed basis in applications that utilize outriggers in severe environments with uneven terrain . Typical appli-cations benefiting from this kit may include but are not limited to; concrete pumpers, digger derricks, and well diggers, see Aftermarket Dual Rebound Strap Kit in this publication .



2 . Remove the ¾" fastener that attaches the rebound strap to the load spring contact plate .

3 . From the inboard side of the saddle remove the ½" fasteners that attach the rebound clip to the load spring bracket .

4 . Slide the rebound clip out of the upper rebound strap loop, see Figure 8-10 .

5 . Remove and discard rebound strap .

ASSEMBLY

THE REBOUND STRAP MUST BE INSTALLED WITH THE SEWN AREA FACING AWAY FROM THE SADDLE AND THE EQUALIZING BEAM . FAILURE TO DO SO WILL RESULT IN PREMATURE WEAR OF THE REBOUND STRAP .

1 . Locate the rebound strap into position, and ensure the sewn area of the loop is facing away from the saddle and equalizing beam .

2 . Slide the rebound clip through the upper rebound strap loop .



3 . From the inboard side of the saddle, mount the rebound clip by installing ½" fasteners . Tighten locknuts to 98 ± 7 foot pounds torque, see Figure 8-11 .

4 . Install the ¾" fasteners into the load spring contact plate and lower rebound strap loop, with the sewn area facing away from the saddle and equalizing beam . Tighten locknut to 50 ± 5 foot pounds torque, see Figure 8-11 .


PRODUCTION DUAL REBOUND STRAPS – OUTRIGGER APPLICATIONSNOTE Prior to installation of the production dual rebound straps service kit, inspect all components of

the HAULMAAX suspension for proper assembly and function, with special attention to the bolster springs . If any damage to the bolster springs is noted, replace prior to installation .

DISASSEMBLY

NOTE Hendrickson recommends replacement of all rebound straps if only one requires replacement .


2 . Remove and discard the inboard and outboard ¾" lower rebound strap to load spring contact plate fasteners, see Figure 8-13 .

3 . Remove and discard the inboard and outboard ½" rebound clip fasteners from the saddle assembly, see Figure 8-13 .

4 . Remove the rebound clips from the saddle assembly .

5 . Remove both rebound straps .FIGURE 8‑12 FIGURE 8‑13

ASSEMBLY

THE REBOUND STRAP MUST BE INSTALLED WITH THE SEWN AREA FACING AWAY FROM THE SADDLE AND THE EQUALIZING BEAM . FAILURE TO DO SO WILL RESULT IN PREMATURE WEAR OF THE REBOUND STRAP .

1 . Slide the rebound clip through the upper rebound strap loop and ensure the sewn area of the loop is facing away from the saddle and equalizing beam .

2 . Locate the rebound clip into position under the saddle assembly, see Figure 8-13 .

3 . Install the upper ½" rebound clip fasteners onto the saddle assembly with the locknuts located under the saddle, see Figure 8-13 .

4 . Tighten upper rebound strap ½" fasteners to 105 ± 15 foot pounds torque, see Figure 8-13 .



5 . Slide the lower rebound strap ¾" bolt though the load spring contact plate and rebound strap .

6 . Install the inboard and outboard ¾" lower rebound strap fasteners and tighten to 52 ± 7 foot pounds torque, see Figure 8-13 .

7 . Repeat procedure for the other side of the suspension .

8 . Remove the wheel chocks from the vehicle .

BOLSTER SPRINGS FIGURE 8‑14

In June 2006, an improved bolster spring package was phased into production for the HAULMAAX 46K suspension system . The design enhancement fea-tures a tie-bar (see Figure 8-14), which connects the bolster springs using a bolt, spacer, and nut . This enhanced bolster spring package applies to the HAULMAAX 46K suspension only . The bolster spring design for the HAULMAAX 40K system remains the same, although a tie-bar kit is available in the after-market for component replacement .

HAULMAAX 46K suspensions must be serviced using the tie-bar bolster spring with wear plate Service Kit No . 64179-048 . Installation of the tie-bar bolster spring is similar to existing bolster springs, with the addition of the tie-bar spacer, bolt and locknut, see Figure 8-14 .

All HAULMAAX 40K suspensions can continue to be serviced using the existing bolster spring Service Kits Nos . 64179-002 and 64179-049 (with wear plate), or can be replaced with the tie-bar bolster spring Service Kit Nos . 64179-037 and 64179-048 .

IF THE WEAR PLATES LOCATED BETWEEN THE EQUALIZING BEAM AND THE BOLSTER SPRINGS / TIE-BAR BOLSTER SPRINGS ARE DAMAGED, THEY MUST BE REPLACED . FAILURE TO DO SO CAN CAUSE DAMAGE TO MATING COMPONENTS .

DISASSEMBLY



2 . From the inboard side of the saddle remove the two (2) ½" fasteners from the rebound clip and remove, see Figure 8-15 .

3 . Loosen, DO NOT remove, the upper eight (8) ½" flange head locknuts connecting the bolster springs / tie-bar bolster springs to the saddle assembly .




4 . Remove the lower eight (8) ½" flange head locknuts connecting the bolster springs / tie-bar bolster springs to the equalizing beam, see Figure 8-16 .

5 . Remove tie-bar bolt and spacer (if equipped) .

6 . Remove the shock absorber (if equipped) fasteners from the upper shock bracket .

7 . Push shock absorber down and clear of the upper shock bracket .

SERVICE HINT It may be necessary to raise the frame of the vehicle to remove the load spring contact plate .

8 . Remove the four (4) fasteners and load spring contact plate spacer (if equipped) that connect the load spring contact plate to the equalizing beam . Remove the load spring contact plate, see Figure 8-17 .

FIGURE 8‑17

NOTE Disconnecting the transverse torque rods will help with bolster spring removal and installation .

9 . Disconnect the transverse torque rods from the frame, and take note of any shims that may be removed .

10 . Raise the rear of the vehicle frame just high enough to remove any contact between the load spring and the top of the load spring contact plate .

11 . Remove the load spring contact plates .

12 . Continue to raise the rear of the vehicle frame to clear the bolster springs / tie-bar bolster springs from the equalizing beam .

13 . Support the vehicle frame at this height .

14 . Remove ½" flange head locknuts that connect the bolster springs / tie-bar bolster springs to the saddle .

15 . Remove the bolster springs / tie-bar bolster springs and wear plates, see Figure 8-18 .

INSPECTION1 . Inspect wear plates for crack damage or if worn through . Replace as necessary .

ASSEMBLY


1 . Mount the bolster springs/ tie-bar bolster springs to the saddle and loosely install ½" flange head locknuts . DO NOT tighten at this time .

2 . By hand, slightly spread the legs of the wear plates to ensure they remain on the bolster while lowering the vehicle . Position the wear plates onto the eight (8) lower bolster spring studs .




3 . Raise the vehicle and remove the frame support . Lower the vehicle and guide the eight (8) lower bolster spring studs into the equalizing beam mounting slots, see Figure 8-18 .

FIGURE 8‑18

4 . Slide the spring contact plates into position . Continue to lower the vehicle and allow the full weight of the vehicle to rest on the bolter springs .

5 . Ensure bolster spring studs sit at the bottom of the mounting slots on the equalizing beam .

6 . If equipped with a tie-bar bolster spring (see Figure 8-19) install:

a . The tie-bar bolt from the out-board side .

b . Install the bolt through the outboard bolster mount, the tie-bar sleeve and the inboard bolster mount .

c . Install the tie-bar locknut and t ighten to 98 ± 7 foot pounds torque .

7 . Install the eight (8) lower ½" flange head locknuts and tighten to 98 ± 7 foot pounds torque .

NOTE Vehicles manufactured from November 2003 through November 2007 require the installation of load spring contact plate spacers between the contact plate and the equalizing beam, see Figure 8-17 . Refer to the Parts List Section of this publication .

SERVICE HINT It may be necessary to raise the frame of the vehicle to install the load spring contact plate .

8 . Mount the load spring contact plate on the equalizing beam by installing the four (4) fasteners, and load spring contact plate spacers (if equipped) . Tighten to 98 ± 7 foot pounds torque .

9 . Lower the vehicle .

10 . Locate the shock absorbers (if equipped) into the upper shock bracket and install the fasten-ers, tighten to 160 ± 10 foot pounds torque .

FIGURE 8‑19



11 . Reattach the transverse torque rods to the frame, ensuring the shims are properly installed Tighten the frame fasteners to vehicle manufacturer’s specifications .

12 . Slide the rebound clip through the upper rebound strap loop .

13 . From the inboard side of the saddle, mount the rebound clip by installing fasteners . Tighten locknuts to 98 ± 7 foot pounds torque .


SHOCK ABSORBERS (if equipped)NOTE It is not necessary to replace shock absorbers in pairs if one shock absorber requires replacement .

NOTE The lower shock stud will be mounted either through a welded bracket on the side of the beam, or a bolt on bracket mounted to the outboard beam hanger leg . The shock absorber is the same for both applications, and the replacement procedure is the same for both .

FIGURE 8‑20

DISASSEMBLY1 . Chock the front wheels of the vehicle .

2 . Remove the 5⁄8" lower shock absorber nylon locknut, retainer washer and lower rubber bushing from the shock absorber stud .

3 . Remove the 5⁄8" fasteners from the upper shock bracket and remove shock absorber .

ASSEMBLY1 . Mount the shock absorber in the upper

shock bracket and install 5⁄8" fasteners . DO NOT tighten at this time .

2 . Locate the lower shock absorber stud in the lower shock bracket and install the rubber bushing, retainer washer and nylon locknut . Tighten to 80 ± 10 foot pounds torque .

3 . Tighten the upper shock absorber 5⁄8" locknut to 160 ± 10 foot pounds torque .


EQUALIZING BEAMNOTE For vehicles built prior to November 2007, when replacing the load spring contact plate or

equalizing beam, Kit No . 57974-046 is required . The kit will include the larger diameter fasteners, instructions to address adjustments necessary, and will eliminate the need for load spring contact plate spacers .

NOTE Whenever an equalizing beam is removed for repair, or inspection of the equalizing beam end con-nection reveals movement, measure the distance between the axle bracket legs for correct width . Refer to Axle Bracket in the Preventive Maintenance Section of this publication for measurement loca-tion and dimensions . An axle bracket outside of the measurement range must be repaired or replaced . Consult the vehicle manufacturer for inspection, component repair and replacement instructions .



DISASSEMBLY




NOTE If both equalizing beams need replacement repeat Steps 2 through 14 for removal of the oppos-ing equalizing beam AFTER the first equalizing beam is reassembled .

2 . From the inboard side of the saddle remove the two (2) fasteners from the rebound clip and remove, see Figure 8-21 .


FIGURE 8‑23

3 . Loosen, DO NOT remove, the eight (8) ½" flange head locknuts connecting the bolster springs / tie-bar bolster springs to the saddle assembly .

4 . Remove the eight (8) ½" flange head locknuts connecting the bolster springs / tie-bar bolster springs to the equalizing beam, see Figure 8-22 .

5 . Remove tie-bar bolt and spacer (if equipped) .Remove the shock absorber fasteners (if equipped) from the lower shock bracket .

6 . Remove the load spring contact plate fasteners and spacer (if equipped, see Figure 8-23) that connect the to the equalizing beam .

7 . Raise the rear of the vehicle frame just enough to remove any contact between the load spring and the top of the load spring contact plate .

8 . Remove the load spring contact plate, see Figure 8-23 .



FIGURE 8‑24

9 . Continue to raise the rear of the vehicle frame to clear the bolster springs / tie-bar bolster springs from the equalizing beam .

10 . Support the vehicle frame at this height .

NOTE Prior to disassembly of the equalizing beam bar pin fasteners, note the orientation of the bar pin align-ment shims, see Figure 8-24 . It is required that the bar pin alignment shims are installed in the same orienta-tion and location as removed to preserve the existing vehicle alignment . Improper vehicle alignment can increase tire wear .

11 . Note the orientation and location of the bar pin shims, see Figure 8-24 .

THE WEIGHT OF THE EQUALIZING BEAM ASSEMBLY IS APPROXIMATELY 155 POUNDS . PRIOR TO REMOVING THE BAR PIN BOLTS FROM THE EQUALIZING BEAM, SUPPORT THE END OF THE EQUALIZING BEAM TO PREVENT FROM DROPPING . CARE SHOULD BE TAKEN AT REMOVAL AND INSTALLATION TO PREVENT PERSONAL INJURY OR DAMAGE TO COMPONENTS .

12 . Support the equalizing beam being serviced .

13 . Remove and discard bar pin fasteners that connect the end bushing bar pin to the axle bracket .

14 . Lower the support and remove the equalizing beam from the axle brackets .

ASSEMBLY


NOTE All equalizing beams are manufactured with the bar pin flats perpendicular to the equalizing beam’s axis . It is not necessary to adjust the bar pins to the same pinion angle as prior to disas-sembly . The rubber in the bushings will gradually allow the bar pins to adapt to the pinion angles of the drive axles . This is a normal function of the bar pin bushings .

SERVICE HINT Installing the front bar pins prior to the rear bar pins will ease in the installation of the equal-izing beam .

THE WEIGHT OF THE EQUALIZING BEAM ASSEMBLY IS APPROXIMATELY 155 POUNDS . CARE SHOULD BE TAKEN AT REMOVAL AND INSTALLATION TO PREVENT PERSONAL INJURY OR DAMAGE TO COMPONENTS .

NOTE Ensure equalizing beams equipped with shock absorber mounting brackets are installed with the shock brackets on outboard side .

1 . Mount the equalizing beam into the FRONT drive axle bracket with the shock mounting brackets (if equipped) on the outboard side . DO NOT install the alignment shims at this time .

2 . Slide a ¾" bolt through the front axle bracket and the bar pin holes to temporarily support the equalizing beam .

3 . Lift the REAR of the equalizing beam until the front bar pin flats are parallel to the front drive axle bracket legs, see Figure 8-25 .

A BAR PIN SHIM MUST BE INSTALLED AT EACH BOLT LOCATION . THE SAME PART NUMBER SHIM IN THE SAME ORIENTATION MUST BE USED AT BOTH BOLT LOCATIONS ON ANY ONE (1) END BUSHING . DO NOT INSTALL OR STACK MORE THAN ONE (1) SHIM AT EACH BOLT LOCATION . USE GENUINE HENDRICKSON BAR PIN SHIMS, DO NOT USE STANDARD WASHERS . FAILURE TO FOLLOW THESE WARNINGS MAY RESULT IN IMPROPER VEHICLE ALIGNMENT, FRACTURE OF THE AXLE BRACKET OR BAR PIN WHICH COULD RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .




FIGURE 8‑27

THE BAR PIN ALIGNMENT SHIM (PART NO . 50130-000) MUST BE INSTALLED WITH THE FOLDED EDGE FACING AWAY FROM THE BUSHING, SEE FIGURE 8-27 . FAILURE TO DO SO MAY RESULT IN SHIM DAMAGE, IMPROPER ALIGNMENT, DAMAGE OR FRACTURE OF THE AXLE BRACKET OR BAR PIN WHICH COULD RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

4 . Partially install the FRONT INBOARD bar pin alignment shim and verify that the shim is in the same orientation as prior to disassembly, see Figure 8-24 .

5 . To complete installation of the alignment shim, remove the temporary ¾" bolt from the inboard bar pin hole and complete installation of the inboard alignment shim .

6 . Install the NEW 1" inboard bar pin fasteners . DO NOT tighten at this time .

7 . Repeat Steps 4 through 6 for the FRONT OUTBOARD bar pin alignment shim .

8 . Chock the REAR drive axle wheels to prevent movement while installing the rear bar pin into the axle bracket .

9 . Support the current axle position of the rear axle pinion with a jack to assist with the installa-tion of the rear bar pin .

NOTE Prior to disassembly of the longitudinal torque rod, note the quantity and orientation of the longi-tudinal torque rod shims . It is required that the longitudinal torque rod shims are installed in the same orientation and location as removed to preserve the existing pinion angle .

10 . Disconnect the rear longitudinal torque rod from the torque rod axle bracket .

11 . Release the rear parking brakes, this will allow the rear axle to rotate without rotating the tires .

12 . Lower the rear drive pinion until the axle bracket legs are parallel to the rear bar pin flats, see Figure 8-26 .

13 . Mount the equalizing beam into the REAR drive axle brackets . DO NOT install the bar pin alignment shims at this time .



14 . Slide a ¾" bolt through the rear axle bracket and the bar pin holes to temporarily support the equalizing beam .

15 . Partially install the REAR INBOARD bar pin alignment shim and verify that the shim is in the same orientation as prior to disassembly, see Figure 8-24 .

16 . To complete installation of the alignment shim, remove the temporary ¾" bolt from the inboard bar pin hole and complete installation of the inboard alignment shim .

17 . Install NEW 1" inboard bar pin fasteners . DO NOT tighten at this time .

18 . Repeat Steps 15 through 17 for the REAR OUTBOARD alignment shim .

NOTE Prior to assembly of the longitudinal torque rod, note the quantity and orientation of the longi-tudinal torque rod shims . It is required that the longitudinal torque rod shims are installed in the same orientation and location as removed to preserve the existing alignment .

FIGURE 8‑28

19 . Raise the rear drive pinion angle to install the longitudinal torque rod and any longitudinal torque rod shims in the same orientation as prior to disassembly . Tighten the fasteners to the vehicle manu-facturer’s specifications .

20 . Re-apply rear parking brake .

NOTE Prior to assembly of the rear fasteners, ensure that all the bar pin shims are installed in the same orientation as prior to disassembly .

21 . Tighten the bar pin locknuts to 525 ± 75 foot pounds torque,

or if tightening on the bolt head, t ighten to 575 ± 75 foot pounds torque .

NOTE If required, repeat the preceding steps to replace the second equal-izing beam .

22 . By hand, slightly spread the wear plates to ensure they remain on the bolster spring while lower-ing the vehicle . Position the wear plates onto the eight (8) lower bolster spring studs .

23 . Lower the vehicle and guide the lower bolster spring studs into the equalizing beam mounting slots until the wear plates and the bolster springs / tie-bar bolster springs are seated against the lower end of the equalizing beam mounting bracket .

24 . Position the load spring contact plates on the equalizing beams .

25 . Ensure bolster studs sit at the bottom of the mounting slots on the equalizing beams .

26 . If equipped with a tie-bar bolster spring, install the tie-bar bolt from the outboard side . Install the bolt through the outboard bolster mount, the tie-bar sleeve and the inboard bolster mount . Install the tie-bar locknut and tighten to 98 ± 7 foot pounds torque .



27 . Install the eight (8) lower ½" flange head locknuts and tighten all sixteen (16) bolster fasten-ers to 98 ± 7 foot pounds torque, see Figure 8-28 .

NOTE Vehicles manufactured from November 2003 through November 2007 require the installation of load spring contact plate spacers between the contact plate and the equalizing beam, see Figure 8-29 . Refer to Parts List Section of this publication .

28 . Mount the load spring contact plate to the equalizing beam by installing the four (4) flange head bolts though the load spring contact plate, contact plate spacers (if equipped) and equalizing beam assembly, see Figure 8-29 . Install flange head locknuts and tighten to

98 ± 7 foot pounds torque .FIGURE 8‑29

29 . Install the shock absorber studs (if equipped) into the lower shock mounting brackets . Install the rubber bushings, retainer washers and nylon locknuts . Tighten to 80 ± 10 foot pounds torque .

FIGURE 8‑30

THE REBOUND STRAP MUST BE INSTALLED WITH THE SEWN AREA FACING AWAY FROM THE SADDLE AND EQUALIZING BEAM . FAILURE TO DO SO WILL RESULT IN PREMATURE WEAR OF THE REBOUND STRAP .

30 . Slide the rebound clip through the upper rebound strap loop, see Figure 8-30 .

31 . From the inboard side of the saddle, mount the rebound clip by installing fas-teners . Tighten locknuts to 98 ± 7 foot pounds torque .




BAR PIN END BUSHINGSYou will need:

■ A shop press with a capacity of at least 100 tons ■ Bar Pin Installation Tool Part No . 66086-103 (OTC Part No . 1757), Removal Tool Part Nos .

66086-104 and 66086-105 (OTC Part No . 206457 and 302030) – Refer to Special Tools Section of this publication

■ A shop made receiving tool, see Special Tools Section of this publication

NOTE Hendrickson bar pin service kits containing alignment shims, (Kit No . 34013-088L) or (Rotating Bar Pin Bushing Kit No . 34013-188) contain all the components required for one (1) equalizing beam end, see Parts List Section of this publication .

WHEN REMOVING AND INSTALLING BUSHINGS IN THE EQUALIZING BEAMS, FOLLOW THE PROCEDURES OUTLINED IN THIS PUBLICATION . DO NOT USE A CUTTING TORCH TO REMOVE THE BUSHING OUTER METALS PRESSED IN THE EQUALIZING BEAM BORES . WELDING, TORCHING OR ATTACHING MATERIAL TO THE EQUALIZING BEAM MUST NEVER BE PERFORMED . THE USE OF HEAT CAN ADVERSELY AFFECT THE STRENGTH OF THE EQUALIZING BEAMS AND CAN CAUSE DAMAGE TO THE EQUALIZING BEAM ASSEMBLY, ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

NOTE Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts . If flange head bolts and locknuts are not used then hardened structural washers must be used under bolt heads and locknuts .

DISASSEMBLY1 . Remove the equalizing beam from the vehicle as detailed in the Equalizing Beam Disassembly

instructions in this section .

2 . Place the equalizing beam in the shop press with the equalizing beam end hub squarely sup-ported on the press bed or receiving tool .


3 . Prior to removal, note the orientation of the bar pin flats, see Figure 8-31 . Mark orientation on the equalizing beam with a paint stick .

4 . Press on the end bushing inner metal, see Figure 8-32, of the end bushing until the inner metal is flush with the top of the equalizing beam end hub . This will dislodge the confinement washer and move the bushing rubber away from the outer metal of the bushing so the removal tool can be installed .

5 . Center the bushing removal tool directly on the bushing’s outer metal and press the bushing out of the equalizing beam end hub .

6 . After removing the equalizing beam end bushings, thoroughly inspect each equalizing beam end hub bore .

INSPECTIONAfter removing the bar pin end bushings, thoroughly inspect the equalizing beam bores . If the equalizing beam is damaged from end bushing removal, replacement of the equalizing beam is required . DO NOT re-bush or otherwise use an equalizing beam that has been damaged .



FAILURE TO REPLACE AN EQUALIZING BEAM THAT HAS BEEN DAMAGED FROM BUSHING REMOVAL CAN RESULT IN THE FAILURE OF THAT EQUALIZING BEAM, LEADING TO ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

When replacing bar pin end bushings, the following steps will help minimize the chance of dam-age during the procedure . FIGURE 8‑33

1 . Clean the end hub bores with emery cloth or hone, removing any nicks or metal buildup from bushing removal .

2 . Measure the equalizing beam end hub bore inner diameter and the bushing outer diameter . The Hendrickson specification for the equalizing beam end hub bore diameter of equalizing beam is 4 .369" / 4 .361" (110 .97 mm / 110 .77 mm), see Figure 8-33 . If components are not within the specified range, replacement is required .

SERVICE HINT The end hub bore may have a more substantial leading chamfer at one end of the bore than the other . Take advantage of the larger chamfer by pressing in the new end bushing from this end .

ALWAYS USE THE BUSHING’S OUTER METAL FOR PRESSING OPERATIONS, UNLESS OTHERWISE INSTRUCTED . PRESSING ON THE BUSHINGS INNER METAL MAY DAMAGE THE BUSHING REQUIRING BUSHING REPLACEMENT .

ASSEMBLY1 . Place the equalizing beam in a shop press with the end hub (see Figure 8-34) squarely sup-

ported on the press bed or receiving tool, see Special Tools Section of this publication .

FIGURE 8‑34

2 . Install Hendrickson part number 66086-103 (OTC 1757) end bushing installation tool (refer to Special Tools Section of this publication) on the new end bushing as shown in Figure 8-34 . Tighten the through bolt until the two (2) halves of the tool touch . The installation tool com-presses the rubber between the inner and outer metal of the bushing to allow press force to be transmitted only to the outer metal of the bushing .

3 . Lubricate the equalizing beam end hub inside diameter AND the bar pin end bushing’s outer metal with a heavy layer of NLGI #2 – EP (Extreme Pressure) lithium base grease, see Figure 8-34 .

4 . Position the equalizing beam end bushing and installation tool on the end hub . Verify the bolt holes in the end bushing are in line with the equalizing beam axis, see Figure 8-35 .



NOTE The end bushing must be square with the equalizing beam end hub before pressing the end bush-ing into the equalizing beam . End bushings pressed in at an angle will damage the end bushing and the equalizing beam .

FIGURE 8‑35

5 . Verify the end bushing’s outer metal is square with the end hub . Equalizing beam and end bushing damage will result if the bushings are pressed in at an angle .

CARE MUST BE TAKEN DURING THE INSTALLATION OF THE BUSHING . DO NOT PUSH ON THE INNER METAL OF THE BUSHING, DOING SO WILL CAUSE DAMAGE TO THE BUSHING AND VOID WARRANTY . FIGURE 8‑36

6 . Install the end bushing into the end hub by pressing on the installation tool until the installation tool contacts the end hub . This will center the bushing in the end hub, see Figure 8-36 .

7 . Install the equalizing beam assembly into vehicle as detailed in Equalizing Beam Assembly in this section .

LONGITUDINAL TORQUE RODS



SERVICE HINT To remove all the load from the longitudinal torque rod, raise or lower the pinion as needed . T h i s w i l l e a s e t h e removal of the longitudi-nal torque rod .

2 . Support the pinion on the axle being serviced .

NOTE Prior to disassembly of the longitudinal torque rod, note the quantity and orientation of the longi-tudinal torque rod shims . It is required that the longitudinal torque rod shims are installed in the same orientation and location as removed to preserve the existing alignment .

3 . Remove the torque rod mounting fasteners and shims (if equipped) .

4 . Remove the fasteners that connect the longitudinal torque rod to the cross member and axle brackets .

5 . Remove longitudinal torque rod from the vehicle, see Figure 8-37 .

ASSEMBLY1 . Verify the length and configuration of the replacement torque rod with the torque rod that

has been removed .



NOTE Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts . If flange head bolts and locknuts are not used then hardened structural washers must be used under bolt heads and locknuts .

2 . Install longitudinal torque rod into position and install the fasteners and any shims that were removed to the cross member and axle brackets . Snug the fasteners .

3 . Verify proper pinion angle, and correct with drop in shims between the torque rod bar pin and the cross member or axle bracket depending on the direction of adjustment needed . Contact the vehicle manufacturer for proper pinion angle specifications .

4 . Tighten all fasteners to vehicle manufacturer’s torque specifications .


TRANSVERSE TORQUE RODS

DISASSEMBLY 1 . Chock the FRONT wheels of the vehicle .

SERVICE HINT Note the quantity and location of shims removed to maintain the lateral alignment of the axle during assembly . See Alignment & Adjustments Section of this publication .

2 . Remove the fasteners that connect the transverse torque rod to the frame and axle brackets .

3 . Using a large hammer, strike the top of axle tower to loosen the taper pin end of the torque rod in the bracket bore .

4 . Remove the transverse torque rod from the vehicle, see Figure 8-37 .

5 . Inspect the mounting surfaces for any wear or damage . Repair or replace as necessary .

ASSEMBLY1 . Verify the length and configuration of the replacement torque rod with the torque rod that has

been removed .

NOTE Hendrickson recommends the using Grade 8 bolts and Grade C locknuts for all torque rod attachments .

2 . Position the transverse torque rod taper pin into the axle tower, and install the frame mount-ing fasteners and any shims that were removed into the frame bracket and outboard support plate . Snug the fasteners .

3 . Prior to tightening, ensure that the vehicle is at the proper ride height .

4 . Install the taper pin locknut, and tighten to 200 ± 25 foot pounds torque .

5 . Tighten all fasteners to the required torque specification . Refer to original equipment manu-facturer for specifications .

6 . Check the lateral alignment . If not within vehicle manufacturer’s specified range, a lateral alignment is necessary . See Lateral Alignment in the Alignment & Adjustments Section of this publication .




TORQUE ROD BUSHINGS

■ ULTRA ROD • ULTRA ROD PLUS BUSHINGS

You will need: ■ A vertical press with a capacity of at least 10 tons ■ Shop made receiving tool and installation/removal tool, refer to the Special Tools Section of

this publication for more information . ■ Funnel Tools Part No . 66086-001 (ULTRA ROD) / 66086-000 (ULTRA ROD PLUS)

1 . Remove torque rods as detailed in Torque Rod Disassembly instructions in this section .

DO NOT USE HEAT OR USE A CUTTING TORCH TO REMOVE THE BUSHINGS FROM THE TORQUE ROD . THE USE OF HEAT WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE ROD, HEAT CAN CHANGE THE MATERIAL PROPERTIES . A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

BUSHING REMOVAL FIGURE 8‑38

1 . Support the torque rod end tube centered on the receiving tool . Be sure the torque rod is squarely supported on the press bed for safe ty .

2 . Push directly on the straddle mount bar pin, see Figure 8-38, until the top of the pin is level with the top of torque rod end tube . Place the push out tool directly on top of the bar pin and press until the bushing clears the torque rod end tube .

3 . Remove the fasteners from the tapered bar pin bushing, and support the torque rod end on the receiving tool with the tapered stud pointing up and the end tube centered on the tool . Be sure the torque rod is squarely supported on the press bed for safety .

4 . Push directly on the tapered stud until the bushing clears the torque rod end tube .

BUSHING INSTALLATION FIGURE 8‑39

1 . Clean and inspect the inner diameter of the torque rod end tubes .

SERVICE HINT DO NOT use paraffinic oil, or soap base lubricant . Such lubri-cants can cause adverse reactions with the bushing, such as deterioration of the rubber, causing premature failure .

2 . Lubricate the inner diameter of the torque rod end hub and the new rubber bushing with P-80 Lubricant or light Naphthenic Base Oil, such as 60 SUS at 100°F, see Figure 8-39 .

3 . Support the torque rod end tube centered on the receiving tool . Be sure the torque rod is squarely supported on the press bed for safety . The straddle mount bar pin bushings must have the mounting flats positioned at zero degrees to the shank of the torque rod, see Figure 8-40 .

FIGURE 8‑40

Straddle Pin Bushing

Taper Pin Bushing



4 . Push directly on the straddle mount bar pin, or the tapered stud . The bushing must be cen-tered within the end tubes of the torque rod .

■ When pushing in the new bushings, overshoot the desired final position by approximately 3⁄16", see Figure 8-41 .

■ Push the torque rod bushing again from the opposite side to center the bar pin, or tapered stud within the end tube, see Figure 8-42 .

IF THE TORQUE ROD ASSEMBLY IS NOT ALLOWED THE ALLOTTED TIME FOR THE LUBRICANT TO DISSIPATE, THE BUSHING MAY SLIDE FROM THE TORQUE ROD END TUBE CAUSING THE BUSHING TO BE REMOVED AND A NEW BUSHING RE-INSTALLED .FIGURE 8‑41 FIGURE 8‑42

5 . Wipe off the excess lubricant . Allow the lubricant four (4) hours to dissipate prior to operat-ing the vehicle .

6 . Replace torque rod assembly as detailed in the Transverse Torque Rod Assembly in this section .

■ XTRB BUSHING FIGURE 8‑43

You will need: ■ A vertical press with a capacity of at least 10 tons ■ Shop made receiving tool and installation / removal

tools, see the Special Tools Section of this publication for more information .

1 . Remove torque rod as detailed in Torque Rod Disassembly instructions in this section .

DO NOT USE HEAT OR USE A CUTTING TORCH TO REMOVE THE BUSHINGS FROM THE TORQUE ROD . THE USE OF HEAT WILL ADVERSELY AFFECT THE STRENGTH OF THE TORQUE ROD, HEAT CAN CHANGE THE MATERIAL PROPERTIES . A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN ADVERSE VEHICLE HANDLING AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE .

BUSHING REMOVAL

SERVICE HINT When servicing a straddle mount bar pin bushing assembly, mark the clocking position of the straddle mount bar pin flats with a paint stick on the torque rod end hub prior to disassembly, see Figure 8-44 . This marking will serve as a guide when installing the new bushing assembly so the original clocking position can be retained .

2 . Mark the clocking position of the straddle mount bar pin flats with a paint stick on the torque rod end hub prior to disassembly, see Figure 8-44 .



FIGURE 8‑44 FIGURE 8‑45 FIGURE 8‑46

3 . Support the torque rod end tube centered on the receiving tool . Be sure the torque rod is squarely supported on the press bed for safe ty .

4 . Push directly on the straddle mount bar pin, until the top of the bar pin is level with the top of torque rod end hub, see Figure 8-45 .

5 . Place the shop made removal tool on the bar pin and press until the bushing clears the torque rod hub, see Figure 8-46 .

6 . Remove the fastener from the tapered bar pin bushing, and support the torque rod hub on the receiving tool with the tapered stud pointing down and the end hub centered on the tool . Be sure the torque rod is squarely supported on the press bed for safety .

BUSHING INSTALLATION1 . Clean and inspect the inner diameter of the torque rod end hubs, see Figure 8-47 .

SERVICE HINT DO NOT use a paraffinic oil, or soap base lubricant . Such lubricants can cause adverse reac-tions with the bushing, causing premature failure .

2 . Lubricate the inner diameter of the torque rod end hubs and the new bushings with NLGI #2 EP grease, see Figure 8-48 .


3 . Support the torque rod end hub centered on the receiving tool . Be sure the torque rod is squarely supported on the press bed for safety .

4 . Re-align the bar pin bushings to the mark made before removal as shown in Figure 8-44 .

5 . Using the shop made tool, place the installer tool on the bushing and press in . The bushing must be centered within the hub of the torque rod .

6 . Wipe off excess lubricant .

7 . Replace torque rod assembly as detailed in the Transverse or Longitudinal Torque Rod Component Replacement Section of this publication .

Mark the clocking position of the bar pin �ats with a paint stick on the torque rod end hub

Inspect and clean the inner diameter of torque rod end hubs

Apply NLGI #2-EP(Extreme Pressure)lubricant to the inner diameter of torque rod end hub and bushings



AFTERMARKET SHOCK ABSORBER KITSService Kit Nos.

■ 64178-003 16½" Saddle Height ■ 64178-004 17½" / 18½" Saddle Height ■ 64178-009 16½" (Mack) Saddle Height

This procedure is intended to assist maintenance personnel with the installation of the Aftermarket Shock Absorber Kit option for vehicles not originally equipped with shock absorbers by the vehicle manufacturer .

NOTE Due to component interference, the HAULMAAX aftermarket shock absorber kits are not compatible with vehicles using dual 315 mm wide tires .

A TECHNICIAN USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOMMENDED BY HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE VEHICLE'S SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED . INDIVIDUALS DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED WILL ASSUME ALL RISKS OF CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED .

DO NOT USE THESE KITS IN CONJUNCTION WITH DUAL 315 MM WIDE TIRES . INSTALLING THESE KITS ON VEHICLES USING DUAL 315 MM TIRES WILL CAUSE CONTACT BETWEEN THE TIRE AND THE LOWER SHOCK MOUNTING BRACKET RESULTING IN TIRE DAMAGE AND POSSIBLE ADVERSE VEHICLE HANDLING, PERSONAL INJURY OR PROPERTY DAMAGE .

INSTALLATIONFIGURE 8‑49

1 . Chock the front wheels of vehicle to prevent movement during installation .

2 . Support axles and frame on stands and remove rear tires .

3 . Starting at the vertical centerline of the suspension outboard frame bracket, measure A in both directions along both vehicle frame rails and draw a vertical line, see Figure 8-49 . Refer to Table 8-1 to determine the correct vertical hole location measurement for the vehicle’s rear axle spacing .

4 . Measure up from the bottom of the frame rail 2½" and draw a horizontal cross line for the lower hole position of the shock frame bracket, see Figure 8-49 .



5 . Drill only for the LOWER HOLES of the shock brack-ets to accommodate the 5⁄8" bolts, see Figure 8-49 .

NOTE If an existing hole is already in the frame rail close to this location, move the location fore or aft by (± 3⁄8") to use the existing hole . DO NOT change the eleva-tion (maintain the 2½" distance from the bottom of the frame rail) of the hole to accommodate an existing hole .

6 . Install the upper shock brackets to frame . Install only the LOWER HOLE shock bracket frame fasten-ers, see Figure 8-49 . Snug the fasteners, DO NOT tighten at this time . Note the upper hole of the shock mounting bracket will be installed in Step 18 .

NOTE The Aftermarket Shock Kits contain longer replacement bar pin bolts needed to accommodate the lower shock bracket .

NOTE The front and rear lower shock brackets are different for Aftermarket Shock Kits 64178-003 and 64178-004 . Only Kit No . 64178-009 (Mack Vehicles) uses the same lower shock bracket for both front and rear . Ensure the proper part is used prior to installation of the lower shock bracket, part numbers are stamped on the bracket .

FIGURE 8‑50

7 . Support the end of the equal-izing beam then remove the existing bar pin fasteners from the outboard side of the equal-izing beam and discard .

8 . Install the FRONT lower shock bracket (Part No . 64148-001) and new fasteners . A 1" flat w a s h e r m u s t b e l o c a t e d between the lower shock bracket and the axle bracket, as shown in Figure 8-50 .

9 . Snug the bar pin fastener, DO NOT tighten at this time .

10 . Repeat Steps 8 and 9 for the REAR lower shock bracket (Part No . 64148-002) .

11 . Install the shock absorber into the lower shock bracket first and then the upper shock absorber bracket .

12 . Attach the lower shock absorber fasteners .

13 . Attach the upper shock absorber fasteners .

14 . Tighten the lower shock absorber fasteners first to 80 ± 10 foot pounds torque, see Figure 8-50 .

15 . Rotate the upper shock mounting bracket to align with the angle of the shock absorbers .

16 . Tighten the upper shock absorbers fasteners to 160 ± 10 foot pounds torque, see Figure 8-50 .

17 . Use the upper shock bracket as a guide to drill the top mounting hole in the frame rail .

TABLE 8‑1

Rear Axle Spacing

Vertical Hole Location

Measure A in both directions from the centerline of the outboard frame bracket

52" 18½"

54" 19½"

60" 22½"

72" 28¾"



18 . Install the top mounting hole fasteners .

19 . Tighten the shock bracket to frame fasteners per the vehicle manufacturer’s specifications .

20 . Tighten the 1" bar pin fasteners: ■ At the bolt head 575 ± 75 foot pounds torque ■ At the locknut 525 ± 75 foot pounds torque

21 . Repeat Steps 3 to 20 for the other side of the vehicle .

22 . Paint as required to prevent corrosion to components .

23 . Install the rear tires .


AFTERMARKET DUAL REBOUND STRAP ENHANCEMENT KIT – for Outrigger Applications

■ 64179-045 Tandem Set ■ 64179-046 Tandem Set with Bolster Springs

Service Kit Nos.

NOTE Prior to installation of the Aftermarket Dual Rebound Straps Enhancement Kit, inspect all compo-nents of the HAULMAAX suspension for proper assembly and function, with special attention to the bolster springs . If any damage to the bolster springs is noted, replace prior to kit installation .

FIGURE 8‑51

INSTALLATIONThis procedure is intended to assist maintenance personnel with the installation, on an as-needed basis, of the Aftermarket Dual Rebound Straps Enhancement Kit for Outrigger Applications Kit No . 64179-045 for HAULMAAX 40K•46K rear suspensions .

Installation of this aftermarket service kit will involve replace-ment of the standard inboard mounted rebound strap and load spring contact plate with a special load spring contact plate, inboard and outboard rebound support blocks (see Figure 8-51) and multiple rebound straps on both sides of the suspension .

All components must be installed per the following instructions .FIGURE 8‑52




1 . Chock the front wheels of the vehicle .

2 . From the INBOARD SIDE of the suspension remove the following components on both sides of the vehicle, see Figure 8-53 .

a . Remove the rebound clip .

b . Remove the 5⁄8" inboard load spring bracket fasteners .

c . Remove the inboard load spring contact plate fasteners .

WHEN RAISING OR LOWERING A VEHICLE ENSURE ALL PERSONNEL ARE CLEAR OF THE VEHICLE . NEVER WORK ON A VEHICLE THAT IS NOT PROPERLY SUPPORTED .

3 . Raise the vehicle frame to create a sufficient gap between the progressive / auxiliary load spring and the shim(s), see Figure 8-52 . Support the vehicle frame at this height .

4 . From the OUTBOARD SIDE of the suspension remove the following components on both sides of the vehicle, see Figure 8-52 .

a . Remove the two (2) M20 outboard saddle fasteners .

b . Remove the outboard bracket fastener . Remove the bracket, rebound support angle, and outboard spacer .

c . Remove the 5⁄8" outboard contact plate fasteners .

d . Lift and remove the contact plate and rebound strap .

PRE‑ASSEMBLY1 . Remove the shims from the current contact plate . Remove contact plate and discard .

2 . Transfer the load spring shims to the new load spring contact plate . Install the bolts through the shims, then through the contact plate . Install locknuts and tighten to 98 ± 7 foot pounds torque, see Figure 8-54 .




ASSEMBLY

NOTE The Dual Rebound Straps Enhancement Kit for Outrigger Applications uses 5⁄8" fasteners to attach the load spring contact plate to the A bracket on the equalizing beam, see Figure 8-56 . Vehicles built prior to November 2007 were manufactured with ½" fasteners and spacers between the con-tact plate and the A bracket, see Figure 8-55 . On these vehicles, the equalizing beam A bracket may require slight modification .

1 . On vehicles built prior to 11/2007 — verify the A bracket will accept a 5⁄8" bolt in the contact plate mounting slot . If a 5⁄8" bolt will not pass through the A bracket then enlarge the slot slightly using a die grinder or file .

NOTE DO NOT install spacers between the contact plate and the equalizing beam A bracket .

FIGURE 8‑56

2 . Position the contact plate on top of the equal-izing beam A bracket . Ensure the arrow on the contact plate points to the outboard side of the suspension as indicated on the con-tact plate, see Figure 8-56 .

3 . Align the holes in the contact plate with the slots in the top of the equalizing beam and install the 5⁄8" bolts through the contact plate then through the equalizing beam A bracket . Install the locknuts on the bolts and tighten to

98 ± 7 foot pounds torque, see Figure 8-56 .

4 . Assemble the new rebound straps and lower mounting fasteners to the new contact plate . Tighten fasteners to 50 ± 5 foot pounds torque, see Figure 8-54 .




5 . Repeat Steps 1 through 4 for the contact plate on the opposite side of the vehicle .

6 . From the OUTBOARD SIDE of the suspension install the following components on both sides of the vehicle, see Figure 8-57 .

a . Position the outboard rebound support block on the saddle and install the two (2) new ¾" saddle fasteners . Ensure the outboard rebound support block is positioned with the rebound clip mounting holes to the outboard side of the suspension, see Figure 8-57 . DO NOT tighten the fasteners at this time .

b . Install the load spring, the load spring bracket, outboard load spring spacer, and the new bracket fastener . DO NOT tighten the fastener at this time .

c . Repeat Steps 6a and 6b on the opposite side of the vehicle .

7 . From the inboard side of the suspension install the following components on both sides of the vehicle, see Figure 8-58 .

NOTE This kit uses an inboard load spring spacer, see Figure 8-58, and DOES NOT use the rebound sup-port angle, shown in Figure 8-52 .

a . Install the inboard rebound support block, load spring bracket, load spring spacer and bracket fasteners . Tighten fasteners to 98 ± 7 foot pounds torque .

b . Repeat Step 9a for the suspension on the opposite side of the vehicle .

8 . Tighten the OUTBOARD SIDE rebound support block fasteners on both sides of the vehicle to the following torque values, see Figure 8-57 .

■ ¾" fasteners – 300 ± 20 foot pounds ■ ½" fasteners – 98 ± 7 foot pounds


WHEN RAISING OR LOWERING A VEHICLE ENSURE ALL PERSONNEL ARE CLEAR OF THE VEHICLE . NEVER WORK ON A VEHICLE THAT IS NOT PROPERLY SUPPORTED .

9 . Remove the frame supports and lower the vehicle onto the ground .

10 . Install the INBOARD rebound clip through the rebound strap and install the fasteners . Tighten fasteners to 98 ± 7 foot pounds torque . Repeat for the inboard rebound clip and rebound strap on the opposite side of the vehicle, see Figure 8-60 .

11 . Install the OUTBOARD rebound clip through the rebound strap and install fasteners . Tighten fasteners to 98 ± 7 foot pounds torque . Repeat for the outboard rebound clip and rebound strap on the opposite side of the vehicle, see Figure 8-59 .

12 . Remove the wheel chocks from the vehicle .

Hendrickson recommended torque values provided in Foot Pounds


Torque Specifications 62 17730-244

SECTION 9

Torque Specifications40K•46K


17730-244 63 Torque Specifications

HAULMAAX 40K•46KHENDRICKSON RECOMMENDED TORQUE SPECIFICATIONS

NO. COMPONENTFASTENER TORQUE VALUE

in foot poundsQuantity Size

Frame Fasteners furnished and installed by Truck Manufacturer

1 Saddle to Outboard Frame Bracket 20 M20 310 ± 30

2 Saddle to Bolster Spring 16 ½"-13 UNC Flange 98 ± 7

3 Saddle to Load Spring Bracket 6 ½"-13 UNC Flange 98 ± 7

4 Load Spring Bracket to Rebound Clip 4 ½"-13 UNC Flange 98 ± 7

5 Inboard Frame Bracket to Outboard Frame Bracket and Cross Member 12

5⁄8" -11 UNC 200 ± 10

M16 *

6 Load Spring Contact Plate to Rebound Strap 2 ¾"-16 UNF 50 ± 5

7 Load Spring Contact Plate to Load Spring Shim 4 ½"-13 UNC Flange 98 ± 7

8 Load Spring Contact Plate to Beam Assembly 85⁄8"-11 UNC Flange **98 ± 7

½"-13 UNC Flange ***98 ± 7

9 Beam Assembly to Bolster Spring 16 ½"-13 UNC Flange 98 ± 7

10 Bolster Spring Tie-Bar 4 ½"-13 UNC Flange 98 ± 7

11aBar Pin Bushing

at the Locknut 8 1"-8 UNC 525 ± 75

11b at the Bolt Head 8 1"-8 UNC 575 ± 75

12 Upper Shock Absorber to Upper Shock Bracket 4 5⁄8"-11 UNC 160 ± 10

13 Lower Shock Absorber to Beam - Nylocknut 4 5⁄8"-11 UNC 80 ± 10

14aTransverse Torque Rod to Axle

at the Locknut 2 1¼"-12 UNF 200 ± 25

14b at the Bolt Head 2 5⁄8"-11 UNC 75 ± 15

NOTE: Torque values listed above apply only if Hendrickson supplied fasteners are used . If non-Hendrickson fasteners are used, follow torque specification listed in vehicle manufacturer’s service manual .

* Not supplied by Hendrickson, for torque requirements see vehicle manufacturer . ** Applies to vehicles built or serviced after 11/07 . *** Applies to vehicles built prior to 11/07 .

Hendrickson recommended torque values provided in Foot Pounds


Torque Specifications 64 17730-244

Production Dual Rebound Straps – Outrigger Applications


17730-244 65 Torque Specifications

PRODUCTION DUAL REBOUND STRAPS – Outrigger ApplicationsHENDRICKSON RECOMMENDED TORQUE SPECIFICATIONS

NO. COMPONENTFASTENER TORQUE VALUE

in foot poundsQuantity Size

Frame Fasteners furnished and installed by Truck Manufacturer

1 Upper Saddle to Lower Saddle 4 ½"-13 UNC Flange 98 ± 7

2 Saddle to Load Spring Bracket 6 ½"-13 UNC Flange 98 ± 7

3 Saddle to Rebound Clip 8 ½"-13 UNC Flange 105 ± 15

4 Load Spring Contact Plate to Rebound Strap 4 ¾"-16 UNF 52 ± 7

5 Load Spring Contact Plate to Load Spring Shim 4 ½"-13 UNC Flange 98 ± 7

6 Load Spring Contact Plate to Beam Assembly 8 5⁄8" -11 UNC 98 ± 7

NOTE: Torque values listed above apply only if Hendrickson supplied fasteners are used . If non-Hendrickson fasteners are used, follow torque specification listed in vehicle manufacturer’s service manual .

Troubleshooting Guide 66 17730-244


SECTION 10

Troubleshooting Guide

HAULMAAXTROUBLESHOOTING GUIDE

CONDITION POSSIBLE CAUSE CORRECTION

Vehicle bouncing excessively

Vehicle not equipped with shock absorbers Install an aftermarket shock kit, see Parts List Section

Leaking shock absorber Replace shock absorber

Damaged or missing shock absorber Replace shock absorber

Suspension has harsh or bumpy ride

Incorrect progressive / auxiliary load spring adjustment

Adjust progressive / auxiliary load spring to proper setting, see Load Springs Adjustment in the Alignment & Adjustments Section

Damaged progressive / auxiliary load spring Replace progressive / auxiliary load spring

Damaged bolster springs / tie-bar bolster springs assembly Replace bolster springs / tie-bar bolster springs assembly

Vehicle leans

Incorrect progressive / auxiliary load spring adjustment

Adjust progressive / auxiliary load spring to proper setting, see Load Springs Adjustment in the Alignment & Adjustments Section

Damaged progressive / auxiliary load spring Replace progressive / auxiliary load spring

Damaged bolster springs / tie-bar bolster springs assembly Replace bolster springs / tie-bar bolster springs assembly

Irregular tire wear Incorrect axle alignment Align axles . Refer to vehicle manufacturer’s specifications

Bulged bolster springs / tie-bar bolster springs

Suspension is overloaded Redistribute load to correct weight and replace bolster springs

Worn progressive / auxiliary load spring Replace progressive / auxiliary load springs and/or shims and replace bolster springs

Axles not centered Center axles under frame rails and replace bolster springs

Loose saddle assembly fasteners

Suspension is overloaded Redistribute load to correct weight

Frequent hard stop/startIncrease fastener inspection intervals

Review driving habits to reduce frequency of hard stop/start

Outboard frame bracket cracked


Loose saddle assembly fasteners Increase fastener inspection intervals

Loose/broken inboard frame bracket Correct inboard frame bracket condition

Loose auxiliary contact plate fasteners


Frequent hard stop/startIncrease fastener inspection interval

Review driving habits to reduce frequency of hard stop/start

Saddle leg to equalizing beam contact

Slipped/loose/broken inboard frame bracket Correct inboard frame bracket condition

Axles not centered Center axles under frame rails

17730-244 67 Troubleshooting Guide


Call Hendrickson at 1.866.755.5968 (toll-free) or 1.630.910.2800 for additional information.

TRUCK COMMERCIAL VEHICLE SYSTEMS800 South Frontage RoadWoodridge, IL 60517-4904 USA1.866.755.5968 (Toll-free U.S. and Canada) 1.630.910.2800 (Outside U.S. and Canada)Fax 1.630.910.2899

www.hendrickson-intl.com

17730-244 Rev I 10-19© 2012-2019 Hendrickson USA, L.L.C. All Rights Reserved. All trademarks shown are owned by Hendrickson USA, L.L.C., or one of the affiliates, in one or more countries.

Information contained in this literature was accurate at the time of publication. Product changes may have been made after the copyright date that are not reflected. Printed in United States of America

Actual product performance may vary depending upon vehicle configuration, operation, service and other factors.All applications must comply with applicable Hendrickson specifications and must be approved by the respective vehicle manufacturer with the vehicle in its original, as-built configuration.Contact Hendrickson for additional details regarding specifications, applications, capacities, and operation, service and maintenance instructions.

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